Non-destructive micro-patterned elastic ultra-thin films for high-resolution skin-like OLEDs

Skin-like organic light-emitting diodes (OLEDs) have garnered attention for their potential in wearable displays, implantable electronics, and biomedical sensing. However, creating high-resolution, mechanically stable OLEDs remains challenging. This study proposes a simple, non-destructive patterning technique to eliminate the thermal expansion mismatch between photoresist and ultra-thin elastomer films. Polyvinyl alcohol is used as a protective layer to allow the elastic ultra-thin films to be micro-patterned to within 2 µm, giving a resolution of up to 6349 pixels per inch (PPI). This work enhances the stability of micro-patterned pixel-defining layers (PDL) in optical manufacturing, thereby contributing to the development of high-resolution displays.