Japanese manufacturer, Dai Nippon Printing Co., Ltd. (DNP) announced that, in May, it commenced operation of a new metal mask production line for manufacturing Organic Light Emitting Diode (OLED) displays at Kurosaki Plant situated in Kitakyushu City, Fukuoka Prefecture.

This step is in response to the increasing demand for larger OLED displays.

Mainly, the new line will produce large-scale metal masks compatible with 8Gen glass substrates for larger OLED displays that are introduced in various IT devices. Particularly, 8Gen substrates are significantly larger than the current 6Gen substrates, facilitating increased production efficiency.

Full-Scale Operation

OLED displays are increasingly being introduced into IT products such as smartphones, tablets, notebooks, and monitors. Particularly, there is a growing need for larger displays. Thus, OLED panel manufacturers are promoting mass production with large 8Gen glass substrates. Particularly, they exhibit a higher production efficiency than the current 6Gen. Anticipating such needs, DNP has established a production system for the manufacture of metal masks compatible with the 8Gen size on the new line at its Kurosaki Plant.

Also, DNP is constantly optimizing its Business Continuity Plan (BCP). It is strengthening responses to minimize the impact on the entire supply chain in event of natural disasters. Further, the company will promote BCP with the start of operations of the new line at the Kurosaki Plant. This makes it possible to provide a backup for its existing metal mask production base at its Mihara Plant, in Hiroshima Prefecture.

With the launch of full-scale operations at the Kurosaki factory, DNP plans to double metal mask production capacity.

DNP Metal Mask Initiatives

To display vivid images on an OLED display, it is important to precisely and accurately position organic materials that emit light in each of the three primary colors, or red, green, and blue (RGB) on a glass or film substrate.

DNP leverages proprietary photolithography and etching technologies with metal masks integrating precisely arranged microscopic apertures drilled into thin metal plates. In turn, these are used in the process of arranging organic material on a substrate. Via a process referred to as Vapor Deposition, in which an organic material is evaporated within a vacuum device and attached to a substrate such as glass or plastic, the metal mask is used to paint each of the RGB colors individually.

DNP began developing metal masks in 2001. Currently, it holds the top global market share, mainly in the area targeting smartphones.

As part of the OLED display production process, vapor deposition in particular, requires advanced technology and know-how. Meanwhile, metal masks also require high dimensional accuracy. As a result, DNP’s high-quality products have developed a firm reputation with manufacturers around the world.

The company constantly pushes the boundaries of technological development to meet diverse needs. It leverages strengths through a broad range of metal mask-related patents and know-how, including materials, manufacturing methods, and products, to supply high-quality, high-precision products in a stable manner.

Looking Ahead

DNP will gradually increase facilities at the Kurosaki Plant, while constantly being aware of, and analyzing demand trends. DNP has designated the Digital Interface-Related business, including metal masks, as a growth area in its medium-term management plan for FY 2023 to 2025, and will strive to further expand business through concentrated investment of management resources.

-13 June 2024-