LG has unveiled a new OLED manufacturing process called FLiPP (FMM-less Innovative Pixel Patterning), which removes the need for the fine metal masks traditionally used to stencil pixels onto panels. These masks are costly to produce and prone to misalignment on larger screens, so eliminating them could allow LG to build brighter, sharper and more durable OLED displays across a much wider range of sizes, from tiny wearables to huge televisions, marking a significant step forward for an already mature display technology.

Instead of using metal masks, FLiPP stencils RGB pixels directly onto panels before using photolithography and UV light to remove unwanted areas. LG says the method produces panels that are 1.6 times brighter, last 2.4 times longer and use 13% less power, while also achieving up to 64% better utilisation of glass substrate in production, cutting material waste and manufacturing costs. The company plans to introduce FLiPP first in tablets and monitors before expanding it to other products, though it has not given a timeline for when the first FLiPP-based devices will reach the market.