Lukas Kosior | XTPL: How can you dispense materials with 1,000,000 cP viscosity at submicron resolutions?

Can additive nano-printing replace 8-step lithography for microLED electrical interconnects?

As microLED chip sizes shrink, forming highly reliable electrical interconnections becomes one of the most critical yield bottlenecks in display fabrication. XTPL's ultra-precise dispensing offers a direct-write alternative to traditional cleanroom photolithography steps, which usually require eight or more processing steps to manufacture microbumps.

The technology prints highly repeatable microbumps down to under 10 micrometers in diameter, maintaining a volumetric deposition variance of less than 10%. This high degree of precision and volumetric control is vital for flip-chip assembly and pixel-level interconnect stability.

Furthermore, this approach allows for the electrical interconnection of complex multi-electrode microLED chips, such as four-electrode designs. By dispensing microbumps directly onto prepared substrates, manufacturers can successfully align, bond, and drive advanced microLED structures with high reliability.

In this short video, you can learn:
* How direct-write dispensing prints microbumps below 10 micrometers with high volumetric consistency.
* The processing advantages of replacing an 8-step cleanroom lithography flow with digital printing.
* How the technology addresses the challenge of interconnecting complex four-electrode microLED designs.
📋 **Clip Abstract** This clip details how XTPL's technology prints conductive microbumps down to sub-10 µm diameters with under 10% volumetric variation, replacing complex multi-step lithography. It demonstrates the direct deposition and assembly process for challenging multi-electrode microLED architectures.
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How do you deposit quantum dots into microcavities at a 3.5-micrometer resolution?

Achieving uniform color conversion is a major challenge for monolithic microLED displays, where blue or UV backplanes require patterned red and green quantum dots. Direct printing of these materials into ultra-small microcavity structures demands extreme spatial resolution and high volume homogeneity to avoid pixel-to-pixel color shifts.

XTPL has partnered with specialist chemistry providers like Custom Dots to optimize quantum dot inks for direct, precise dispensing inside these tiny microcavities. This process achieves highly uniform cavity filling, meeting the tight optical and thickness tolerance specifications required for commercial-grade displays.

To push the limits of resolution, the technology can dispense individual quantum dot micro-dots as small as 3.5 micrometers on planar substrates. This capability proves that the system can support sub-5-micrometer pixel pitches, paving the way for ultra-high-density microdisplays used in augmented reality.

In this short video, you can learn:
* The process of precisely dispensing and filling microdisplay cavities with quantum dot materials.
* How collaborative material tuning enables stable and highly uniform nano-printing processes.
* The scaling limits of quantum dot dispensing, down to individual 3.5-micrometer micro-dots.
📋 **Clip Abstract** XTPL demonstrates direct-write nano-dispensing of quantum dot color conversion materials into microdisplay cavities with high volumetric homogeneity. The process achieves feature sizes down to 3.5 µm, pointing to high-resolution color-conversion capabilities for AR-grade microLED microdisplays.
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