What it takes to introduce a new tech like micro LED.

Micro LED technology is going to be stop-you-in-your tracks amazing. Whether it’s a big screen TV in your living room wall or the beautiful dashboard of your car (see the latest blog!), it’s going to be really cool. Many companies are working hard to differentiate their LCD offerings and capitalize on the energy anticipating the arrival of micro LED displays by creating their own demos using micro and mini LEDs, showcased at trade shows around the globe, but the products have yet to drop for the average consumer.

The technology required to deliver these products to consumers has many layers, including the technology for placement of the very tiny LED, the end-to-end SMT manufacturing process, leading edge materials and micro drivers, the best optical stack up integration, and bezelless edge design to deliver a beautiful finished product to consumers. 

First, a process that can handle mini and micro LEDs requires a placement robot that can place the microscopic die (roughly the size of a speck of dust) with speeds and yields at levels that become economically viable for consumer products. That placement robot has to be able to touch each individual die, ensure top speeds, and best-in-class accuracy to achieve the highest uniformity of light for the end product.  Speeds have to reach a certain level of units per hour (UPH) to achieve economic viability for the end consumer products. A micro LED-lit TV will have millions of die, and they each need to be individually placed. 

The speed at which the placement process happens leaves little room for error, but when a defect happens, there must be a solution in place to handle these defects. An inline automated rework solution can remedy any defects real-time.  The six sigma quality requirements for it to be economically viable is ensuring there is only 1 bare die rework in over 100,000 micro LED die placed.

Rohinni has patented a process that fulfills the light layers for consumer products, but now the total supply chain needs to be primed and ready for delivering an entirely new product for consumers to have in their hands.

To speed up the adoption by the supply chain, it is necessary to communicate the full value proposition to increase demand.  Product designers, engineers, and consumers alike should understand the flexibility that these amazing microscopic light layers offer. Mini and micro LED substrates offer the same high value as traditional packaged LEDs and LED light engines with the additional benefits of flexible substrates for curved designs, being thinner, each LED individually addressed for zoning and animation.  They also offer longer lifetime of light output in comparison to OLED, along with lower power consumption overall.

Most importantly, the new products with micro LED light layers will be absolutely beautiful. People who have seen micro LED products in comparison to traditional LCD backlit products say there is no comparison to the picture quality and we just can’t wait. 

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