DuPont has just made a major breakthrough on the road to cheaper OLED displays. The company has developed an advanced new printing process that allows them to create larger, tougher OLED screens in bulk. The MIT Technology Review says that DuPont can print a 50” television in less than two minutes. Stress testing gives the device a shelf-life of some 15 years.
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Traditional OLED production relies on something called shadow-mask evaporation. This method is highly inefficient for anything but tiny displays, which is why LG's 15” monitor costs nearly 3 grand. Printing is much more effective, especially for larger devices, but it requires very special inks that did not exist until very recently.
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DuPont's new inks contain active molecules that make them insoluble with inks in other layers. This stops bleeding and makes OLED production feasible on a large scale. DuPont plans to license their manufacturing process and inks to display manufacturers. I think I speak for everyone who has ever used an OLED display when I say this cannot happen quickly enough.