Organic solar cells (OSCs) have been gaining great popularity in recent years due to their potentials to be low cost, lightweight, and flexible. The performance of OSCs is growing steadily, and they have achieved a power conversion efficiency close to 10% (for single-junction polymer-fullerene OSC). Although there are still limitations and challenges faced by the development of OSCs, in view of the potentials, recent studies have been focusing on the design optimization of OSC layer structure through material engineering, interfacial layer insertion, layer thickness optimization, and morphological control. In this paper, we provide a comprehensive review and detailed discussion on the optimization works and development on OSCs, with particular focus on the bulk-heterojunction (BHJ) polymer-fullerene OSCs. We also provide a summary of the performance, in a chronological order, and the future outlook of OSC.