We propose a cost-effective, mask-free fabrication process for high-density organic photovoltaic (OPV) modules based on oblique vacuum-deposition of small molecules over nozzle-jet printed microstructures. The contact angle of these microstructures is varied through surface modification, enabling them to function selectively either for separation or for passivation. An area utilization ratio as high as 95.6% with respect to a designated illumination area is demonstrated with the proposed method in series-connected OPV modules based on active layers of C-70 doped with di-[4-(N,N-ditolyl-amino)-phenyl] cyclohexane (TAPC) molecules. (C) 2013 Elsevier B.V. All rights reserved.