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Samsung Display is working on new OLED panel production methods that could significantly reduce manufacturing costs in the future. The South Korean manufacturer is developing two technologies in parallel that would allow it to do away with traditional metal masks. One of them could result in savings of more than 30%.
Samsung wants to move away from metal masks
Currently, the production of many RGB OLED panels uses FMM (Fine Metal Mask) technology. It involves depositing organic materials through extremely thin metal masks with microscopic openings. The solution provides precision, but it is costly, uses a lot of material, and makes it difficult to produce larger panels.
Samsung Display is therefore testing two alternatives. The first is inkjet printing, meaning depositing red, green, and blue emissive materials directly onto the substrate. According to Korean ETNews, the company is already in talks with suppliers about building a pilot production line. If the necessary production efficiency is achieved, the new method could theoretically cut production costs by more than 30%. However, that does not mean an equally large drop in prices of finished devices.
Second technology and a 7-inch prototype
Meanwhile Samsung is developing its own MPO (Micro Patterned OLED) method, which uses photolithography and microscopic structures that separate subpixels. It reduces material usage and avoids some processing steps for the organic layers. According to The Elec, the company is preparing an OLED panel prototype about 7 inches diagonally. An engineering sample is expected to be ready by the end of 2026, though work could extend into the first quarter of 2027.
It’s worth noting that Samsung is not alone. LG Display is developing a competing FLiPP technology, while China’s TCL CSOT has already started producing OLED panels using inkjet printing.
For now, the most likely applications for the new solutions are laptop and monitor displays. In the longer term, the development of cheaper manufacturing methods could also matter for the OLED TV market. However, Samsung has not given a date for the start of mass production nor decided on the final choice of technology.
Sources: The Elec, Oled-info
