The mini-slot-die coater offers a simple, convenient, materials-efficient route to print bulk-heterojunction (BHJ) organic photovoltaics (OPVs) that show efficiencies similar to spin-coating. Grazing-incidence X-ray diffraction (GIXD) and GI small-angle X-ray scattering (GISAXS) methods are used in real time to characterize the active-layer formation during printing. A polymer-aggregationphase- separation-crystallization mechanism for the evolution of the morphology describes the observations.