The Terefilm photopolymer is an innovative material utilized by Terecircuits to facilitate the mass transfer of microLED components. This material is crucial in achieving sub-micron accuracy for the placement of microLEDs, a necessary feature given their minute size. MicroLEDs can be as small as 5-50 microns, which makes traditional methods incapable of efficiently processing them.
One of the significant challenges in assembling microLEDs is their requirement for precise sub-micron placement, as any misalignment could drastically affect performance. Terefilm Photo-polymer allows for rapid transfer and placement of microLED components with ease, overcoming the limitation of current manufacturing processes that could take days to assemble large numbers of components.
This material works through a photo-activated process. A donor plate is used to pick up thousands of microLEDs directly from wafers, holding them at the fabrication pitch. Using an opaque mask and light activation, only select microLEDs are released onto the display substrate at a desired pixel pitch. This cycle is repeated until the entire substrate is populated efficiently and accurately, facilitating faster and more cost-effective manufacturing of microLED displays.
