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Binary-Solvent-Programmed Single-Step Inkjet Printing of Self-Confined Micro-Inlaid OLED Arrays.

JaeWoo Park1,2, Wonsun Kim3, Kimin Lee3

  • 1Materials Science and Engineering, Fulton Schools of Engineering, Arizona State University, Tempe, Arizona, USA.

Small Methods
|June 16, 2026
PubMed
Summary

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This summary is machine-generated.

A novel inkjet micro-inlay process uses solvent programming for self-confined organic light-emitting diode (OLED) pixels. This method achieves uniform, high-performance µ-OLED arrays without photolithography, enabling scalable flexible and 3D OLED fabrication.

Area of Science:

  • Materials Science
  • Organic Electronics
  • Nanotechnology

Background:

  • Inkjet printing offers mask-free fabrication for large-area electronics.
  • Achieving uniform micron-scale organic light-emitting diode (µ-OLED) arrays via inkjet printing remains a significant challenge.
  • Existing methods often require complex photolithography steps.

Purpose of the Study:

  • To develop a photolithography-free, single-step inkjet micro-inlay process for fabricating uniform µ-OLED arrays.
  • To enable self-confinement of emissive pixels through lateral phase separation.
  • To optimize solvent interactions for improved µ-OLED performance and uniformity.

Main Methods:

  • A solvent-programmed, single-step inkjet micro-inlay process was developed.
Keywords:
Hansen solubility parametermixed‐solvent interactionphase separationsingle‐step inkjet printing, micro‐inlaid OLEDµ‐OLED arrays

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  • A binary solvent blend of trichloromethane (TCM) and 1,2-dichloroethane (DCE) was designed based on solubility parameters.
  • Characterization involved micro-Raman mapping, cross-sectional SEM, and AFM phase analysis.

    • Main Results:

    • Lateral phase separation successfully self-confined emissive pixels to approximately 100 µm.
    • The process yielded reproducible 180 dpi µ-OLED arrays with high uniformity and no jetting instability.
    • Green µ-OLED arrays demonstrated a peak luminance of 2400 cd m⁻², peak current efficiency of 3.5 cd A⁻¹, and peak external quantum efficiency of 1.0%.

    Conclusions:

    • The developed solvent-programmed inkjet micro-inlay process enables mask-free, scalable fabrication of uniform µ-OLED arrays.
    • This strategy significantly improves luminance uniformity and figure of merit compared to neat solvents.
    • The technique facilitates the creation of flexible and 3D conformal OLED platforms.