Organic photovoltaics (OPVs) are a recent technology that has gained much attention as a potential low cost power source. Despite this promise, there is a lack of published studies that address the likely cost of commercial-scale OPV modules. In this work, an engineering study estimate has been performed to determine the projected cost of mass-manufactured OPV modules. The materials, production capital and operating costs have been calculated and sensitivity analyses performed to determine the parameters of greatest economic influence. Significantly, the model includes a calculation of the costs required to establish bulk manufacturing of the current high cost speciality materials components, encompassing synthesis and associated chemical plant design. The economic modelling reveals that the calculated mass-manufactured OPV module costs are considerably lower than current literature estimates, with OPV modules costed at $7.85 per square metre with an uncertainty of +/- 30%. Total module cost was found to be most sensitive to the plastic substrate prices, while the production rate did not have a significant impact on module cost for rates above similar to 50 m(2)/min. The results highlight the future cost potential of OPV technology and can be used to assist with scale-up planning. (C) 2013 Elsevier B.V. All rights reserved.