OLED industry targets cost reduction through mask reduction and new patterning technologies

At the SigmaIntel Display Summit, industry experts discussed critical technological shifts aimed at reducing OLED manufacturing costs and enhancing performance for next-generation devices. A primary focus is the reduction of mask counts in the lithography process. Currently, high-end smartphone OLED panels can require up to 30 masks, which increases production time, equipment burden, and defect rates.

High Mobility Oxide (HMO) is emerging as a key solution to replace LTPO technology. HMO aims to provide the high electron mobility required for high-resolution, high-refresh-rate displays while maintaining a lower mask count similar to standard oxide TFTs. SigmaIntel predicts Apple will lead HMO adoption, starting with the Apple Watch in 2027 and expanding to iPhones and iPads by 2028.

Simultaneously, manufacturers are pursuing FMM-free (Fine Metal Mask) technologies. Visionox is implementing its Intelligent Pixelization (ViP) technology, which uses photolithography instead of traditional metal masks to improve pixel aperture and sensor space. LG Display is also developing its FLiPP patterning technology to increase brightness and lifespan while reducing power consumption. These innovations are seen as essential for the growth of the AI glasses and XR markets, where high-resolution microdisplays like OLEDoS are increasingly vital.