Mask-free fast patterning of organic light-emitting diode pixels using laser-assisted close-space sublimation

Abstract

Existing patterning processes for organic light-emitting diode displays offer micrometer-scale precision but are constrained by long processing times for large-area substrates. In this work, we study a fast growth method for patterned organic film deposition, aimed at applications including active-matrix organic light-emitting diode displays. The approach employs a specially engineered donor substrate in a close-space sublimation configuration combined with laser heating. The donor substrate incorporates spatially patterned absorber and reflector layers that enable selective, one-step or two-step transfer of organic material onto a receiver substrate. We analyze the optical response and heat-transfer dynamics that govern the selective transfer mechanism and demonstrate precise pixel patterning with micrometer-scale spatial fidelity. The reliability and practical applicability of the method are validated by fabricating light-emitting diode devices by using this rapid transfer process and benchmarking their performance against devices produced via conventional vacuum thermal evaporation. The resulting devices exhibit comparable optoelectronic performance, confirming the robustness and technological relevance of the proposed strategy for scalable fabrication of patterned organic light-emitting diodes for display application.