LG Display has unveiled its next-generation technology, FLiPP, which enhances productivity and reduces cost burdens compared to traditional organic light-emitting diode (OLED) manufacturing methods. The key innovation lies in eliminating expensive metal masks and improving manufacturing efficiency by utilizing existing production equipment.
On October 8, LG Display held an online tech seminar to present the competitiveness of its self-developed OLED patterning process, FLiPP, and its future business strategy. FLiPP is a new technology that removes the fine metal mask (FMM) used in conventional OLED production and precisely forms light-emitting pixels.
In the traditional FMM method, a metal plate with tiny holes is placed over a glass substrate to deposit red, green, and blue (RGB) light-emitting materials. In contrast, FLiPP applies light-emitting materials across the entire substrate and retains only the necessary areas. This process employs photolithography technology used in semiconductor manufacturing, allowing pixel formation without a metal mask.
The strength of FLiPP lies in its productivity. The existing 8th generation FMM process requires cutting large glass substrates in half to prevent sagging of the metal mask. FLiPP eliminates the need for a metal mask, allowing the full use of the 8th generation substrate.
As a result, the panel area that can be produced from a single glass substrate increases. According to LG Display, the yield efficiency for producing 23.5-inch panels using the FMM method is about 75%, while FLiPP achieves over 93%. This expansion in usable area leads to a productivity increase of approximately 24%.
The efficiency of light-emitting material usage also improves. The FMM method incurs material loss during the substrate cutting process, resulting in a deposition efficiency of about 40%. In contrast, FLiPP utilizes the entire substrate, raising material efficiency to 74%, nearly 1.9 times higher than the previous method. This reduction in the use of expensive OLED light-emitting materials is expected to contribute to cost savings.
Process time is also reduced. The FMM method requires repeated alignment and replacement of the metal mask each time light-emitting materials are deposited. FLiPP applies an inline deposition method used in large OLED production, streamlining this process. By continuously moving the glass substrate during deposition, FLiPP can cut deposition time by about 40% compared to FMM.
Cost efficiency is another competitive advantage of FLiPP. FMM requires high-cost components that must be custom-made for each product size and resolution. The production of masks, as well as the need for precise alignment equipment and maintenance personnel, adds to manufacturing costs, along with defects caused by mask sagging or foreign substances.
Kim Eung-yong, a member of LG Display, stated, "Creating new FMM masks for each model costs hundreds of millions of won. FLiPP not only reduces mask production costs but also improves defects caused by sagging or foreign substances."
The ability to reuse existing equipment also favors cost reduction. LG Display plans to leverage its white OLED (WOLED) mass production technology and 8th generation production infrastructure accumulated since 2013 for FLiPP. Some equipment will be modified, and only necessary new equipment will be added, minimizing the investment burden associated with establishing new production lines.
Choi Young-seok, LG Display's Chief Technology Officer (CTO), emphasized, "By utilizing existing infrastructure, we can produce regardless of product size and type, achieving significant results with relatively lower costs compared to new investments in 8.6-generation technology."
The performance improvement of products is also substantial. FLiPP increases the aperture ratio, which is the proportion of the actual light-emitting area, from 42% to 65% by eliminating the metal mask and reducing the gap between pixels. This allows for a brightness increase of 1.6 times or a lifespan extension of 2.4 times compared to the FMM method. It is also reported that power consumption can be reduced by 13%.
LG Display plans to initially apply FLiPP technology to IT OLEDs, such as laptops and monitors, and later expand its application to wearables and large-screen TVs based on market demand. Theoretically, FLiPP can be implemented for screens ranging from small 1-inch displays to over 100-inch large screens.
However, it may take some time before mass production begins. Currently, FLiPP is in the technology development stage, and the timing for mass production will be determined after securing customers and developing products. The final reduction rate in panel manufacturing costs has not yet been specifically disclosed.
CTO Choi stated, "FLiPP is a technology that condenses 22 years of OLED technology and know-how accumulated by LG Display, and it will be a turning point that changes the paradigm of the display industry."
* This article has been translated by AI.
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