With the rapid advancement of prototypes and the initial launch of commercial products, MicroLED display technology is steadily progressing toward commercialization. However, significant challenges such as manufacturing complexities, low yield rates, and high costs continue to hinder its entry into the mass consumer market. At DisplayWeek 2023, the state and future paths of MicroLED commercialization were explored through demos, panel discussions, and business meetings. Various MicroLED prototypes, including different sizes, pixel densities, and dimensions, were showcased for applications like augmented reality, wearable devices, laptops, and automotive displays. MicroLED is poised to surpass LCD and OLED with superior color reproduction, brightness, reliability, and energy efficiency.
MicroLED Production Capacity: Gaining Momentum
MicroLED displays are self-emitting, consisting of MicroLED arrays where each LED functions as a pixel. These displays can be integrated heterogeneously—transferring chips from epitaxial wafers to display backplanes—or monolithically, where arrays and integrated circuits are built on a single backplane. Production is improving in all critical areas, including chip efficiency, transfer yield, and manufacturing capacity. Brands, display manufacturers, and LED suppliers are increasing investments in technological development and manufacturing capabilities, forming numerous partnerships across the supply chain.
According to Yole Research, Apple and its partners plan to invest over $2 billion in building an 8-inch MicroLED chip factory for smartwatch displays, targeting completion by the end of 2024. Crystal Electric will establish a 6-inch MicroLED foundry using PlayNitride technology, supported by AU Optronics, which aims to start producing a 1.39-inch smartwatch display in Q4 2023. JBD has already begun production in Hefei, with a total capacity of 120 million 0.13-inch MicroLED panels. Many other companies have set up pilot production lines, and Samsung plans to increase its MicroLED TV production in 2023.
Equipment manufacturers are also developing tools specific to MicroLED manufacturing, including those for transfer quality, testing, and repair, which are expected to shorten development cycles and enhance production capacity. Toray is working on “laser direct transfer” technology suitable for large-size substrates, promising higher throughput and reduced costs. Toray and Advantest are collaborating to create testing and inspection tools that improve process yields, while InZiv focuses on high-throughput EL detection tools for MicroLED wafers, targeting up to 12 million chips per hour by 2024.
Color Conversion Solutions in MicroLED Displays
One of the main challenges in producing MicroLED displays is accurately and efficiently bonding RGB MicroLEDs to the display backplane, as the voltages and drive currents required for different colors vary. Color conversion using quantum dots (QDCC) or phosphors offers an alternative solution. Using monochrome (blue) MicroLED chips combined with a QD layer for color conversion can simplify manufacturing.
Nanosys presented at DisplayWeek that “QDCC on UV MicroLED achieves high brightness, excellent color quality, and high resolution through economical and efficient manufacturing.” Applied Materials has introduced a scalable method for manufacturing MicroLED displays using efficient UV MicroLEDs and in-situ cured cadmium-free RGB quantum dot formulas. This method has been applied to produce a 1.37-inch smartwatch display prototype, featuring high efficiency and improved manufacturing yields.
AU Optronics has also developed a rollable MicroLED display using color conversion technology. Their presentation at DisplayWeek highlighted that the “thermal effect of luminous efficiency remains a key issue for MicroLEDs.” AUO’s approach incorporates a color conversion layer to form red sub-pixels, which enhances display reliability even at high temperatures.
MicroLED Microdisplays: The Future of AR Solutions
With the rising interest in the metaverse, many companies see augmented reality (AR) as the next computing platform. AR glasses need to be lightweight while offering bright, high-contrast content and extended battery life. MicroLED microdisplays are considered the most promising solution for AR, requiring high pixel density and small pixel spacing.
JBD has developed monolithic monochrome displays and compact multicolor projectors by combining three independent monochrome panels. Recently, they announced a new red MicroLED light engine with a size of 2 microns and brightness up to 750 nits. Porotech showcased a full-color 0.26-inch, 1280×720 MicroLED microdisplay panel for AR applications. PlayNitride introduced a novel Chip-on-Carrier step to enhance transfer yield and processing time for AR/MR displays.
Market Applications of MicroLED: Continued Expansion
According to DSCC, “MicroLED displays manufactured through mass transfer are expected to find applications in smartwatches, TVs, and cars.” Smartphones may not adopt MicroLED technology soon due to higher costs associated with the increased number of pixels compared to smartwatches.
VueReal has developed new pixel and MicroLED structures that reduce the size of MicroLEDs below 10 microns, helping to cut costs and expand production for smartwatches and smartphones. Their technology, demonstrated at DisplayWeek, shows scalability and cost efficiency.
Several MicroLED prototypes were showcased at DisplayWeek 2023, highlighting the technology’s versatility across various applications:
- LG Display: 12-inch stretchable display with 20% stretchability, RGB color, and 1,000 nits brightness.
- AU Optronics: 14.6-inch rollable display, 1,000 nits brightness, and high contrast ratio.
- PlayNitride: 0.49-inch FHD MicroLED microdisplay for AR glasses.
- JBD: 0.13-inch monolithic MicroLED microdisplay for AR, already in production.
- Tianma: 8.7-inch transparent MicroLED for automotive applications.
While high-speed transfer, yield management, and supply chain development are critical for mass commercialization, the commercial success of MicroLED displays will hinge on achieving mass production at a competitive cost-performance ratio.
Source: MicroDisplay
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