…And…

…And…
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AP Systems (aka APS Holdings) has announced that they have been able to create an OLEDoS (OLED on Silicon) display with a resolution of 3,000 PPI, after reaching the 1,000 PPI mark earlier this year.  While such resolutions have been reached using OLED and color filter systems (see above), APS accomplished this resolution using RGB patterning and no color filter.   An APS subsidiary was responsible for the deposition and encapsulation, which was done with a FMM (Fine Metal Mask) that is placed over the substrate during OLED material deposition.  The small holes in the mask direct the OLED material pattern, although typical masks have been unable to gain this level of refinement as the smaller the patterning holes get, the more the mask can flex, leading to misplaced materials, and making the mask thicker allows for OLED materials to collect more quickly on the mask and the thicker hole sidewalls create ‘shadows’ that also misalign materials.
APS creates its masks using a laser to create the mesh, while typical masks are produced using etchants.  APS has championed the laser mask process over the etch process during a government funding bake-off and seems to have been successful, as its current mask for the 3,000 PPI display is 8um thick, while masks used in generic smartphones are 18um, with both being made of the same iron-nickel alloy.  While there are still production issues when working at such higher resolutions, APS seems to be going in a direction that will move the AR/VR display hardware side more rapidly ahead, and given its relationship with Samsung Display, we expect they will play an additional role in SDC’s AR/VR display project mentioned above.

FMM Shadow Issue - Source: SCMR LLC