Roll-to-roll manufacturing of epi-GaN sheets on metal foil for LEDs and transistor devices

iBeam Materials has demonstrated a new technology to fabricate GaN devices directly on polycrystaline metal foil. This new technology is based on ion-beam crystal alignment to make templates for epitaxial GaN films on flexible metal foil. Thus far iBeam has demonstrated high-quality epi-GaN and GaN-based LEDs and HEMT devices on up to 4-inch scale. However, our approach will eliminate the traditional restrictions for manufacturing in wafers, allowing for scaled-up roll-to-roll processing and opening up possibilities for new classes of products in lighting, signage, displays and instrumentation. These products will be enabled by the ability to make large-area flexible sheets of GaN at low cost. In particular, sheets of LEDs produced by roll-to-roll manufacturing, will allow for large-area monolithic integration of LEDs and active transistor devices for display applications. MicroLED displays made on robust sheets of thin metal foil will enable super-bright, power-efficient, paper-thin and flexible displays.