This work is aiming to develop photovoltaic modules from flexible polymer solar cells based on materials existing on the market. In several steps the influence of the series resistance on polymer solar cell performance is reviewed. Based on these experimental and theoretical investigations an optimal design for highly efficient polymer solar modules is developed. As a next step to the realization of flexible polymer photovoltaics, the proper technical approach to process larger area flexible substrates is required. In this case for production on laboratory scale, the doctor blading technique and other coating techniques have been applied. The separation of individual solar cells has been obtained by wet chemical etching and prospect is given for use of laser ablation. A combination of coating and laser ablation techniques paves the way towards a roll-to-roll production.