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InnovativeHigh-PerformanceDepositionTechnologyforLow-CostManufacturingofOLEDLightingProgressReviewJohnW.HamerOLEDWorksLLC2014-05-071OLEDWorksIntroduction•WearetheonlyUSmanufacturerofOLEDlightingpanels.•FoundedinRochesterNYin2010•22full-timeOLEDexperts–Over200yearsofcombinedOLEDexperience–ExperienceacrossallareasofOLEDtechnology•BuiltastateoftheartOLEDR&Dlab•Designedandstarted-upanovel,flexible,scalableOLEDproductionfacility.•Wehavecommercializedourfirstproduct.•Weworkwithmanypartners:–SupplierstotheOLEDlightingindustry–Downstreamluminairepartners.2014-05-072InnovativeHigh-PerformanceDepositionTechnologyforLow-CostManufacturingofOLEDLighting•Forournovelapproachtovaporization,control,anddistributionoforganicvapor,theprojectencompasses:–Designoftheproduction-scaleequipmentofthedepositionequipment,–Testing,analysis,andimprovementoftheequipment,–Implementationintoproductionwithdemonstration•Thegoalsofthisdepositionsystemare:1.Improvematerialusageefficiency2.Improvedepositionrate–higherthroughput3.LeadtolowercapitalcostOLEDdepositionmachines4.EnableuseofthermallysensitivematerialsDOESSLMfgWorkshop2014-05-073ReferenceMachines•ThemostcommonOLEDlightingsysteminproduction/pilottodayisSunicG2–370x470mm–E.g.LGChem,FirstO-Lite,COMMED–Thisisthelargestpubliclydisclosedproductionmachineinusetoday(370x470mm)•Futuresystem–G5-1100x1300mmDOESSLMfgWorkshop2014-05-074StandardAssumptions:80%uptime,80%yield,80%glassusageefficiency5yearstraightlinedepreciationGen2BaselineGen5FutureGlassSize370x470mm1100x1300mmMaterialusage15-25%60%TACtime2-6min1-2minSubstrateVelocity1.3-4mm/sec9-18mm/secOperatingTimebetweenloading6days6daysAreaofGoodproduct8,000-12,000m2/year190,000-380,000m2/yearEstimatedCapitalCostofWholeline$50-100M(use$75M)$150-300M(use$200M)Depreciationperunitofproduction$600-1900/m2$100-200/m2SunicG2ApproximateParametersSunicG5ProjectTargetsinTermsofReferenceMachinesDOESSLMfgWorkshop2014-05-075Gen2BaselineGen5FutureGlassSize370x470mm1100x1300mmMaterialusage15-25%60%TACtime2-6min1-2minSubstrateVelocity1.3-4mm/sec9-18mm/secOperatingTimebetweenloading6days6daysAreaofGoodproduct8,000-12,000m2/year190,000-380,000m2/yearEstimatedCapitalCostofWholeline$50-100M(use$75M)$150-300M(use$200M)Depreciationperunitofproduction$600-1900/m2$100-200/m2•Theroughgoalsoftheprojectaretodesignandbuildvaporgenerationanddepositionsourcestoenable:–CapitallikeG2-$50-100M–MaterialusagelikeG5-~60%–SubstratespeedlikeG5–9-18mm/sec–DepreciationlikeG5-$100-200/m2–Easyonheatsensitivematerials•Unfortunatelywecannotshowthedesignofourproductionmachineorthedesignofthenewvaporgenerationanddepositionssources.•However,wewilldescribetheapproach,considerations,andprogress.Motivation–WhythisprojectisimportantDOESSLMfgWorkshop2014-05-076DOESSLMYPPApril2014TABLE4.5OLEDPANELANDLUMINAIREMILESTONES“Meetingthepanelpricegoalof$200/klmby2015,orsoonthereafter,seemsnecessaryinordertocreatealargeenoughdemandtojustifyfurtherinvestmentsinR&Dandmanufacturingcapability.Theluminairepricegoalof$80/klmisappropriatefor2020ifOLEDsaretogainsufficientmarketpenetrationtocontributesignificantlytoglobalenergysavings.”Motivation–Whythisprojectisimportant20122013201620202025IntegratedSubstrate5002501504020OrganicDeposition1,4006002507030AssemblyandTest6003502005020Overhead(incllabor)5003001002010Total(unyielded)3,0001,50070018080YieldofGoodProduct(%)15%25%70%75%80%TotalCost20,0006,0001,000240100DepositionMachineSizeG2G2G2G5G5TACTime(min)66221Depreciation(atcapacity,afteryield)10,2576,154733222104TotalCostwithDepreciation30,25712,1541,733462204FractionofTotalCostduetoDep.34%51%42%48%51%GrossMargins50%50%50%50%50%SalesPriceofPanels60,51424,3083,465923408Priceoflight($/klmat10klm/m2)6,0512,4313479241DOEMilestones(2014DOEMYPP)200inFY15CostofLuminaire&ChannelCosts4x4x4x4x4xSalesPriceofLuminaire242,05597,23313,8613,6941,632Priceoflight($/klmat10klm/m2)24,2069,7231,386369163DOEMilestones(2014DOEMYPP)80DOESSLMfgWorkshop2014-05-077Withthecurrentequipment,wedonothittheDOEmilestonesforindustrysuccess.Table1-6OLEDPanelCostEstimatedProgress($/m2)fromSept‘13DOESSLMfgRoadmapCostandPricesRelativetoDOETargetsDOESSLMfgWorkshop2014-05-07805001,0001,5002,0002,5003,0003,5004,0004,5005,0002012201420172020202320252028CostandPrice($/m2)YearPriceandCostofOLEDPanelsandLuminairesSalesPriceofLuminaireSalesPriceofPanelsTotalCostwithDepreciationTotalCost(COGS)w/oDepreciationDepreciation(atcapacity,afteryield)2015DOEGap2020DOEGapCostdataisfromDOESSLMfgRoadmapSept2013PricetargetdataisfromDOESSLMYPPApril2014Gapsbetweentargetpriceandpredictedprices:•2015-~3-5x•2020-~4-5xWeneedinnovationinequipmentperformance(cost,throughput,flexibility)tohelpreachthetargetsLarge-ScaleProductionOLEDDepositionEquipmentVacuumThermalEvaporationofOrganics•OrganicVaporGenerationanddepositionsectionsDOESSLMfgWorkshop2014-05-079ReferenceExample–Sunic1G5(1100x1300mm)1SID2013,Paper55.4DevelopmentofHighlyProductiveIn-lineVacuumEvaporationSystemforOLEDLighting,J.M.LimetalNozzleDesignDOESSLMfgWorkshop2014-05-0710•G5nozzlesat250mmdistanceachieve60%materialusag