Improving light extraction for OLED devices will be pivotal for their acceptance into the marketplace. Incorporating
nanostructures within the high refractive index regions of the OLED multi-layer stack results in an over two-fold
improvement in light extraction efficiency. Such nanostructures were made using roll-to-roll fabrication processes. We
will also discuss the performance characteristics of the nanostructures on color-angularity and blurring of high-resolution
Over the years there have been demonstrations of various methods capable of forming
sub-micron features such as photo, electron beam, and imprint lithography. Generally
these methods are limited to planar master tools of limited dimensional size. The
subsequent replication processes using these master tools are typically a batch or a rollto-
roll process with a tiled master roll tool. Presented here is a novel method for the large
scale manufacturing of sub-micron structures via a roll-based mastering method suitable
for industrial scale, based on a modification of single point diamond turning.
Single point diamond turning has been exploited successfully to generate a wide range of
optical structures from discrete optical components to large area micro-optic based films
such as brightness enhancement films (BEF) for LCD displays. By applying advanced
ion-milling techniques to structure diamond tools, it is possible to increase the
complexity and ultimate dimensional resolution of diamond machined masters.