From MicroLED to OLED and flexible display architectures, Sono-Tek’s ultrasonic spray technology delivers the ultra-uniform, material-efficient coatings demanded by next-generation display processes. Our systems are enabling innovators to explore and scale new coating solutions — from proven production applications to advanced R&D programs developing tomorrow’s display materials.
Flux Deposition and Emerging Coating Applications
Sono-Tek plays an active role in helping MicroLED developers improve manufacturing reliability and accelerate R&D toward scalable production.
Our proven application is in flux deposition for mass transfer and interconnect formation, where precise, uniform coatings directly enhance yields. We also support extensive research efforts into encapsulation and other advanced coating steps under evaluation for future MicroLED architectures.
Flux Deposition on Bonding Pads (Pre-Reflow) — Proven Application
Ultrasonically applied, microns-thin flux films on the backplane’s pads improve wetting and joint quality during mass transfer/reflow. Precision control of film thickness and uniformity can significantly improve yield consistency, using Sono-Tek’s well-established ultrasonic fluxing systems.
Encapsulation & Process Development — Active R&D
Sono-Tek systems are being evaluated in MicroLED R&D for several emerging coating uses, including:
- Thin-film encapsulation and planarization layers: Exploratory work on spray-deposited organic and hybrid coatings that may enhance barrier performance and optical uniformity.
- Color-conversion and underlayer coatings: R&D use of ultrasonic spray for large-area and underlayer film deposition supporting color-conversion material development. These coatings are used to evaluate new quantum-dot or polymer formulations prior to patterned or pixel-level processing.
- Surface primers and protective overcoats: Investigations into low-velocity, low-shear deposition techniques that safeguard delicate MicroLED die and backplanes.
Why Ultrasonic Spray Coating for MicroLED Works
- Excellent uniformity and step coverage across micro-scale features
- High transfer efficiency, reducing waste of costly chemistries
- Same deposition physics from benchtop R&D to pilot-scale systems
- Compatible with diverse solvent systems and viscosities used in display process development
OLED Encapsulation and Layer Deposition
Sono-Tek’s ultrasonic spray systems are widely used in OLED process development and manufacturing evaluations, particularly for thin-film encapsulation (TFE) and barrier layer coatings. Our low-energy, non-contact spray ensures uniform, defect-free films that protect sensitive organic layers while maintaining optical clarity.
Applications include:
- Hybrid organic/inorganic stack primers – wetting layers that improve adhesion and barrier performance
- Planarization films – sub-micron coatings to smooth surface topography before barrier or emissive layers
- Getter coatings – controlled dispersion of moisture-getter materials within polymer matrices
These precise coating capabilities are helping OLED manufacturers and researchers improve device lifetime, yield, and surface quality.
Flexible and Foldable Displays
As displays evolve toward flexible and foldable formats, Sono-Tek’s coating systems are being adopted for barrier, primer, and planarization layers on polymer, foil, and flexible glass substrates.
Our non-contact spray process enables:
- Uniform coatings on thin, bendable surfaces
- Excellent edge control and step coverage
- Integration with roll-to-roll or sheet-fed pilot lines
These capabilities are ideal for next-generation display programs where durability, optical quality, and process scalability are critical.
Advanced Nano-Film and Display Research
Sono-Tek has participated in numerous display research initiatives developing new nano-films and material stacks for advanced display applications. Researchers rely on our controllable ultrasonic atomization for precise, repeatable coatings with minimal material waste.
Active research areas include:
- Quantum dot and color conversion coatings
- Conductive or dielectric nano-layers
- Novel encapsulation barrier formulations
- Experimental optical and surface modification coatings
With decades of thin-film expertise, Sono-Tek supports the transition from early-stage R&D to scalable, manufacturable processes for emerging display technologies.
Why Sono-Tek for Advanced Display Manufacturing
- Exceptional uniformity and controllable film thickness
- Low-velocity, non-contact process ideal for sensitive or flexible substrates
- High material efficiency, especially with expensive or experimental materials
- Scalable solutions from research to pilot and production environments