AP Systems Revolutionizes OLED Display Production With DPSS Lasers

Industry Challenges: Staying ahead of the next generation beyond the next generation

Founded in 1994, AP Systems has established a strong reputation in the semiconductor equipment market based on their equipment control software knowledge and integration expertise. Their business coverage includes mid to small-sized LCD equipment, semiconductor processing equipment for 300mm wafers, and large-sized LCDs. They are leaders in advanced ELA (Excimer Laser Annealing), LLO (Laser Lift-Off), and OLED Encapsulation, which are the laser equipment necessary to produce OLED panels.

In the fiercely competitive world of OLED display manufacturing, AP Systems faced escalating demands for cost reduction, improved productivity, and advanced automation. As the industry expanded to larger format displays, new technologies were required to meet the challenges of stability, precision, and 24/7 uptime in increasingly automated production environments. The exceptional performance of VYPER excimer gas laser systems from Coherent comes with demands for regular operational maintenance.

“Intensifying competition among display manufacturers pushed us to address the limitations of conventional ELA systems and explore cutting-edge solutions,” said AP Systems’ John Bae, Equipment Sales Head, Sr. VP. “Our long-standing collaboration with Coherent enabled us to tackle these challenges head-on, leveraging their expertise in lasers and optics.”

The Solution:  PYTHON Laser and SLA Systems

The primary goal of generation 8.6 investments in OLED display manufacturing is to reduce production costs through higher productivity, higher uptime, and a higher grade of automation. However, to achieve this business goal, it is imperative that new generation equipment integrate with existing production processes. Building new production lines in purpose-built facilities is an order of magnitude greater expense than retrofitting existing production lines with new generation systems.

To meet these demands, AP Systems partnered with Coherent to integrate the revolutionary PYTHON laser into their next-generation G8.6 SLA (Solid Laser Annealing) system. Based on DPSS (Diode Pumped Solid State) technology, the PYTHON laser offered extended operational lifespans, lower maintenance requirements, and superior stability compared to its predecessor, the VYPER laser. This integration resulted in:

• Improved Beam Performance: Enhanced stability led to dramatic reductions in substrate defects, such as shot mura, expanding the process window and improving OLED display performance and longevity.
• Seamless Integration: The classic yet forward-thinking design approach facilitated smooth integration of the PYTHON laser with AP Systems’ G8.6 demo system.
• Future-Ready Design: The PYTHON laser maintains the performance and outline of the existing VYPER laser while adopting the same optical system design as the ELA system. This enables it to achieve Line Beam performance equal to or better than that of ELA, while preserving ELA's process records intact. This signifies that SLA can achieve the same process quality as ELA in the upcoming G8.6 process expansion.

Achieving Breakthroughs: From Demo to Full Production

The partnership’s success culminated in the deployment of SLA demo systems, which received overwhelmingly positive feedback from major display manufacturers. These demo systems not only validated the performance of the SLA technology but also laid the groundwork for future fab investments.

“Our SLA demo systems have been a game-changer,” shared AP Systems’ John Bae. “Customers value the opportunity to directly evaluate processes, and the results are setting new benchmarks for OLED display production.”

Realizing Results: Boosting Efficiency and Customer Satisfaction

The integration of the PYTHON laser into the SLA system delivered tangible benefits, including:

• Cost Reduction: By improving laser lifespan and reducing maintenance, the solution aligned with manufacturers’ goals of cutting production costs.
• Enhanced Productivity: Stable raw beam performance increased process efficiency and ensured consistent output, meeting the growing demands for high-quality displays.
• Futureproofing: With its scalable design, the SLA system positions AP Systems to lead the industry in adopting advanced technologies for high-end OLED displays.

Looking Ahead: A Collaborative Path to Innovation

Building on their success, AP Systems and Coherent are poised to continue driving innovations in OLED manufacturing. The PYTHON laser and SLA systems will play a pivotal role in addressing the evolving demands of display makers, ensuring larger screens, higher performance, and enhanced user experiences.

“Our collaboration with Coherent has enabled us to transform the OLED manufacturing landscape,” concluded John Bae. “Together, we are not only meeting today’s challenges but shaping the future of high-end displays.”

This customer success story demonstrates how advanced laser technology from Coherent and the collaborative approach are empowering industry leaders like AP Systems to redefine OLED production and set new standards for performance and efficiency.

Learn more about the groundbreaking PYTHON laser and the challenges Coherent overcame to deliver it.