Materials‐Engineered Isolation Architecture Enables Ultra‐Uniform Inkjet Printing for Mura‐Free OLED Displays

ABSTRACT The mass production of large‐area organic light‐emitting diode (OLED) displays via inkjet printing is severely constrained by mura defects, which arise from non‐uniform droplet deposition caused by microfluidic crosstalk in multi‐nozzle printheads. Conventional approaches often rely on complex electronic compensation, which offers limited efficacy as they do not address the physical root cause of the interference. This work presents a materials‐science‐based solution: a novel printhead design incorporating a physically engineered isolation architecture, realized with high‐modulus ceramic materials to mechanically decouple adjacent nozzles. Using a validated multi‐physics simulation framework that couples structural analysis with computational fluid dynamics (CFD), we systematically engineered the architecture and investigated the performance of various ceramic materials, including alumina and aluminum nitride (ALN). A direct correlation between the material's Young's modulus and crosstalk suppression was established. The optimized design, featuring a 1.0 mm thick isolation wall made of 99.8% alumina (Young's modulus: 370 GPa), achieves an unprecedented droplet volume deviation of less than 0.3%. This study demonstrates a paradigm shift toward passive, materials‐based solutions for controlling complex microfluidic systems, offering a direct engineering pathway for the high‐yield manufacturing of mura‐free displays and other advanced printed electronic devices. A novel inkjet printhead design eliminates mura defects in OLED manufacturing. By incorporating a physical isolation wall made of high‐modulus ceramic, mechanical cross‐talk between adjacent nozzles is effectively suppressed. This materials‐based solution achieves ultra‐uniform droplet deposition (<0.3% deviation), enabling the high‐yield production of large‐area, high‐quality OLED displays.