In the micro-world, every millimeter of perfection represents the ultimate exploration of technology. As Micro LED technology leads the display revolution, who is behind illuminating this visual feast with dazzling brilliance?
Today, we explore an extraordinary piece of equipment: the first glass-based Micro LED wafer inspection system independently developed by KOALA URAN. This breakthrough addresses the challenges in high-end display manufacturing, using precise inspection to guide KOALA URAN as it leads the new era of industrial inspection powered by AI.
1. Why Is a TV So Expensive?
How expensive can a TV be? If I told you that one TV costs as much as a house, it would shatter your perception. Samsung’s MNA110MS1ACXXZ model TV is priced between $60,000 to $100,000, while the 114-inch giant TV released this year can cost as much as $125,000.
This luxurious TV offers not just financial shock but also a new understanding of technological excellence. What justifies its sky-high price is Micro LED, hailed as the “future of perfect display technology,” which supports the price of $10,000 per inch.
2. What Is Micro LED?
Micro LED, with diameters ranging from 5μm to 100μm, is about the size of a tiny dust particle in the air.
Having surpassed the eras of LCD and OLED technologies, Micro LED has become the new favorite in the industry. With its small chip size, low power consumption, high brightness, high resolution, and fast response speed, it is widely applied in various fields including wearables, monitors, car tail lights, wireless optical communications, AR/VR, and projectors.
Imagine, in the future, as Micro LED displays reach mass production, not only will prices drop, but high-end display technology will become more accessible, enabling electronic devices with both portability and long-lasting power efficiency.
3. The “Bottleneck” Problem Behind Its Vast Prospects
A major highlight of Micro LED technology is its extremely small size. However, as LED chips get smaller, the precision required during manufacturing increases significantly. It’s like trying to place millions of tiny sand particles with micrometer-level precision—just a tiny mistake could ruin everything.
Moreover, high-resolution displays demand more Micro LED chips. For example, a 4K display has up to 16 million pixels (counting only the monochrome chips). Even with a 99.99% transfer yield (transfer yield refers to the ratio of defect-free chips successfully transferred to the display), hundreds of defective chips can still be expected.
If defects are not detected and fixed before the bonding process, subsequent processing becomes much more difficult, and product yield is impacted.
In other words, the appearance of the chip determines whether it is usable, and the position offset determines whether it can be accurately transferred to the target location on the backplane. To achieve large-scale production of Micro LED displays, it is crucial to tackle the problems of appearance inspection and position deviation. This is why the entire industry is actively seeking effective methods and technologies to solve defects and improve yield.
4. KOALA URAN’s Breakthrough: China’s First Micro LED Wafer Inspection Equipment
In August this year, KOALA URAN developed China’s first glass-based Micro LED wafer inspection system, filling a significant gap in the domestic market. This breakthrough brings a local solution to the Micro LED industry and will reverse the longstanding dependence on imported equipment in China.
This industry-leading innovation has demonstrated exceptional performance in real-world applications. The equipment boasts high precision, stability, and efficiency, capable of handling over 50 different types of products with ease. It has already successfully completed mass production testing, and its detection capabilities have been highly praised by customers.
Similar to the meticulous checks done on each component of a rocket before launch in aerospace engineering, Micro LED chips must undergo precise identification for appearance defects and position deviations before transfer and bonding. KOALA URAN’s device plays this critical role, measuring both appearance defects and positional misalignment with remarkable accuracy.
The system’s adjustable optical magnification is particularly impressive: at 20x magnification, the optical accuracy can reach 0.16μm. This means it can easily detect Micro LEDs as small as 5μm in diameter, ensuring that no micro-defect or deviation goes unnoticed during the inspection and analysis process.
Additionally, KOALA URAN‘s self-developed AI algorithm uses active learning to not only accurately detect appearance defects but also categorize them precisely. This method enables quick, personalized defect repair solutions and facilitates rapid process optimization—improving both quality and efficiency.
In terms of position measurement, the system uses calibration and coordinate transformation methods to eliminate system errors caused by motion and distortion, keeping errors under ±0.5μm. This ensures the precise assembly of Micro LED chips and the high quality of the final product.
Statistics show that KOALA URAN’s production efficiency is three times higher than that of a leading international competitor.
5. KOALA URAN Pioneering the Future of Industrial Inspection with AI
As a leader in providing multi-modal large model industry solutions, KOALA URAN is dedicated to building integrated solutions that combine multi-modal industry models, industry-specific models, and industry applications. The company has been nurturing new productivity and driving the industrial application of AI technology across various sectors.
With extensive practical experience in industrial AI inspection applications, the company focuses on optical, software, electrical, and mechanical systems to provide comprehensive solutions for industries such as semiconductors, large-scale inspections, and high-end display manufacturing.
KOALA URAN has already launched a range of inspection equipment including LED wafer COW/COT inspection devices, graphic wafer AOI devices, glass surface and edge defect detection AOI, photoelectric glass large-scale inspection AOI, lead frame plastic sealing AOI, GDS1 inspection devices, miniLED backlight bulb AOI, miniLED module AOI, and automotive TP inspection devices.
In November, KOALA URAN was recognized as a key player in the AI industry chain in Chengdu, with its AI+ intelligent inspection applications included in the Chengdu AI+ Application Case Collection.
About KOALA URAN
KOALA URAN is a leading provider of multi-modal AI industry application solutions. The company was founded by Professor Shen Hengtao, a foreign academician of the European Academy of Sciences and an ACM/IEEE/OSA Fellow, along with over 20 Ph.D. graduates from renowned institutions worldwide. With the self-developed global first multi-modal AI operating system – MAJIK, KOALA URAN launched the YuRAN multi-modal industry general model and its application platform, which focuses on the generation and application of multi-modal industry-specific AI models. This platform enables rapid construction of industry-specific AI applications, serving over 500 customers globally across sectors like high-end display manufacturing, semiconductors, tobacco, railway transportation, ecological environment protection, and urban governance. KOALA URAN remains committed to advancing core multi-modal AI technologies and collaborating with industry partners to build a world powered by AI.
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