The Future of OLED Manufacturing

Report Summary

Although active matrix OLEDs have become a $40B market, they are far from a mature technology. OLEDs have significant potential for more growth and are still evolving in terms of cost and performance. In addition, now that MicroLEDs are emerging, OLEDs are under greater pressure to boost performance and lower cost and we are seeing a number of efforts in parallel to significantly improve OLED cost/performance to prevent MicroLEDs from taking share. OLEDs are also aggressively moving into new markets and are tailoring future performance and cost improvements to enter these new segments. This report will examine how OLED panel manufacturers and materials suppliers are looking to boost performance and lower cost and enter new markets, growing the OLED market to well over $50B.

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    January 2024
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What is driving the OLED market forward?

  • SDC’s desire to stay ahead of its Chinese OLED competitors;
  • Apple’s desire to extend its OLED position in smartphones to tablets, notebooks and even desktop monitors. The migration to larger sizes is fueling interest in larger OLED substrate manufacturing.
  • Chinese OLED manufacturers efforts to narrow the performance and manufacturing gap with SDC and LGD;
  • Threats from MiniLEDs today and MicroLEDs in the future.
  • Capturing the opportunity in AR/VR

Panel suppliers and brands alike have looked to OLEDs for differentiation and higher margins than in the commodity LCD market. OLEDs have already established a strong position in smartphones and a high-end niche in TVs. This report will address how OLED manufacturers will look to boost their position in smartphones and TVs and establish a growing foothold in the IT market. These advances will be necessary to push OLEDs from $40B to well over $50B in revenues.

The report is divided into smartphone, IT, TV and AR/VR sections and will address in each the technology roadmap, performance outlook, cost outlook, manufacturing challenges and solutions, ways to reduce costs and OLED’s position vs. competing technologies. The adoption of G8.7 substrates for the IT market plays a critical role in this report and will examine the risks and rewars, new capabilities such as IGZO backplanes, high mobility IGZO backplanes, FMM VTE patterning, FMM-less patterning, high resolution lithography, high efficiency blue OLED emitters, tandem stacks, color on encapsulation, multi lens arrays and more to improve OLED’s competitiveness in IT and other markets.
The report also addresses the challenges in Micro OLEDs for AR/VR, why yields are poor, how companies are looking to boost yields, the latest demand and supply outlook and much more.

The Future of OLED Manufacturing Report is a must read for any company in the display industry. It is helpful for executives, strategists, technologists, marketing, sales, engineers and more.

Table of Contents

1.0 Executive Summary p. 3

2.0 Background – OLED Status p. 29
2.1 Display Revenues by Technology and Application p. 30
2.2 Display Units and Area by Technology and Application p. 35
2.3 OLED Supplier Share p. 39
2.4 OLED Fab Schedule and Capex Forecast p. 42
2.5 OLED Capacity Forecast p. 45

3.0 Technical Challenges and Bottlenecks for OLEDs p. 59
3.1 Known Historical Production Challenges p. 61
3.2 Current OLED Yield Challenges p. 73
3.3 Current OLED Material Challenges p. 83
3.4 OLED’s Cost Challenge p. 85
3.5 Micro OLED Yield and Cost Challenges p. 88

4.0 OLEDs in Smartphones and Wearables p. 91
4.1 Overview and Latest Forecast p. 92
4.2 Low Frequency LTPS and Other Power Saving Developments p. 99
4.3 LTPO p. 103
4.4 Color on Encapsulation p. 115
4.5 Micro Lens Arrays/Patterns p. 121
4.6 Apple’s iPhone Roadmap p. 125
4.7 Under Panel Cameras and IR Sensors p. 128
4.8 High Resolution Lithography and Maskless Lithography p. 148
4.9 Mobile OLED Stacks p. 157
4.10 Deuterium p. 163
4.11 Double CPL and Patterned CPL p. 166
4.12 Phosphorescent Blue OLED Emitters for Mobile p. 169
4.13 Plasmonics p. 175
4.14 Foldables and Rollables p. 177

5.0 OLEDs in IT p. 191
5.1 The IT Opportunity and Apple’s IT OLED Roadmap p. 192
5.2 Current OLED Notebooks, Tablets and Monitors and Panel Roadmaps p. 200
5.3 The Challenge/Problem and Panel Requirements p. 214
5.4 G8.7 IT OLED Backplane Challenges p. 221
5.4.1 Scaling LTPO p. 223
5.4.2 Oxide and LTPO+ p. 230
5.4.3 High Mobility Oxide Benefits and How to Boost Mobilities p. 239
5.4.4 High Mobility Oxide Challenges and Solutions p. 244
5.4.5 Glass Thinning p. 283
5.5 G8.7 IT OLED Frontplane Challenges p. 287
5.6 Alternative Patterning Approaches p. 292
5.7 Tandem Stacks – Benefits and Challenges p. 302

6.0 OLEDs in TVs p. 309
6.1 Overview p. 310
6.2 WOLED p. 312
6.3 QD-OLED p. 326
6.4 OLED Materials for TVs p. 336
6.5 RGB IJP OLED Status p. 346
6.6 OVJP Status p. 373

6.7 Auxiliary Electrodes p. 379
6.8 Other Emissive Candidates p. 383
6.9 Cost and Shipment Forecasts p. 385

7.0 OLEDs in AR/VR p. 390
7.1 Why Micro OLED for AR/VR? p. 391
7.2 Fab Schedules and Capacity p. 397
7.3 Supply Chain p. 404
7.4 Performance and Design Requirements p. 413
7.5 WOLED with Single and Tandem Stacks p. 421
7.6 Direct Patterning p. 431
7.7 Micro OLED Architecture with MLA p. 438
7.8 Micro OLED Forecasts p. 442

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