† Electronic Supplementary Information (ESI) available: SC and WBC drying kinetics measurements. UV-vis absorption spectra of SC and WBC PCDTBT:PC60BM blend layers. PL spectra of SC and WBC blended layers and their respective PCDTBT neat layers. EQE of blend devices deposited by SC and WBC techniques. Optical microscopy images of the blend layer deposited by SC and WBC on SiOx (as cast) and PEDOT:PSS (at 80°C and 140°C thermal annealing temperature). SeeWe demonstrate that organic solar cells can exhibit different morphological and performance stability under thermal stress depending upon the processing technique employed, without compromising initial device efficiency. In particular, we investigate benchmark PCDTBT:PC60BM solar cells fabricated by wire bar coating (a technique attractive for commercial manufacture) and the more widely employed, lab scale, technique of spin coating. For this system, wire bar deposition results in superior device stability, with lifetime improvements in excess of 20-fold compared to spun cast devices. Neutron reflectivity reveals that the enhanced PC60BM segregation to the top interface in the slower, wire bar, casting process is likely responsible for the hindered PC60BM nucleation at tens of nm length scale, characterized by atomic force microscopy (AFM), and thus enhanced morphological stability. Modest light exposure of the active layer (at approximately 10 mWcm -2 ), known to reversibly photo-oligomerize fullerenes and thus impart morphological stability, is found to further improve device stability by a factor of 10. The combined effects of wire bar coating and light processing are highly synergetic, resulting in solar cells which are overall 200 times more stable than devices prepared by spin casting without light processing.