This study investigates the 3D active surface area of flexible organic solar cells, micro-fabricated using novel microfabrication procedures. A fully functional 3D organic solar cell is first micro-fabricated using negative photolithography procedure followed by the deposition of orgacon, P3HT:PCBM and aluminum layers. We then characterize the 3D solar cell in terms of the total available surface area, and workable efficiency. Moreover, the dependence of spacing between the adjacent micro-pillars on surface area and efficiency of the 3D organic solar cell is further analyzed. Novel photolithography procedures have been designed to achieve micro-pillars with varying aspect ratios, with spacing as low as 10_m between the adjacent pillars.