Overcoming four major pain points, Chenxian Optoelectronics reshapes Micro-LED mass production logic

At this year's two major events in the LED display industry, ISLE 2026 and infocomm2026, as a pioneer in the field of Micro-LED industrialization, Chenxian Optoelectronics made a grand appearance with a TFT-based Micro-LED product matrix, including a 270-inch 8K TFT-based Micro-LED display, a 13.55-inch P0.7 TFT-based Micro-LED large module display, and a 19-inch P0.4 TFT-based Micro-LED transparent screen, 27-inch P0.7 TFT-based Micro-LED textured screen and many other world-first innovative products.

With its innovative applications covering multiple scenarios and disruptive visual effects performance, Chenxian Optoelectronics has fully demonstrated its profound accumulation in Micro-LED technology research and development and mass production to the industry, becoming one of the highlights of the exhibition.

8K TFT-based Micro-LED display

The evolution of this series from prototype to mature product matrix not only highlights Chenxian Optoelectronics’ leading position in technology research and development and product innovation in the field of Micro-LED, but also clarifies a new path for the technological evolution and application expansion of the new display industry.

At the 2026 TrendForce New Display Industry Symposium (DTS 2026), Yao Zhibo, a senior researcher at Chenxian Optoelectronics, deciphered how the company can quickly achieve these impressive industrialization results through TFT-based Micro-LED technology.

Yao Zhibo, senior researcher at Chenxian Optoelectronics

Why does Chenxian Optoelectronics firmly choose TFT glass base?

In the process of exploring the path of Micro-LED display technology, the choice of substrate directly determines the physical performance and display upper limit of the final product. Chenxian Optoelectronics has firmly chosen TFT glass as the core technology.

Compared with traditional PCB substrates, TFT glass substrates have extremely high physical stability and flatness. After long-term use or exposure to heat, the PCB substrate is prone to slight warping and deformation, which is fatal for large-size displays that pursue the ultimate visual effect. The glass substrate has superior hardness and temperature-resistant thermal expansion coefficient, and can accurately control the physical seams within 20 microns.

The advantages of this substrate are not only reflected in its physical form, but also in its compatibility with advanced drive technology. TFT glass base can realize complex semiconductor process technology, thus supporting AM (active matrix) driving method.

Unlike the PM (passive matrix) driver commonly used in traditional PCB-based LED products, AM driver can achieve independent and precise control at the pixel level. In terms of image quality performance, the AM driver completely eliminates screen flicker or bright lines that may be caused by high-frequency scanning, making the image more stable and even. In terms of energy efficiency management, AM drivers can effectively reduce instantaneous brightness and extend the lighting duration, thereby significantly reducing power consumption.

According to test data disclosed by Chenxian Optoelectronics, its TFT-based Micro-LED display has a power consumption of only 250W/m2 at a brightness of 600nits. Compared with PCB-based Mini-LED displays, its energy-saving efficiency has increased by approximately 37%.

More importantly, lower power consumption means less heat generation, and the temperature rise (ΔT) of the screen surface can be controlled within 15°C. This "cold screen" feature is crucial for close viewing scenarios such as high-end home theaters in the future. It not only improves physical comfort, but also meets the stringent certification requirements for energy consumption and safety of home appliances.

At the same time, the high-precision manufacturing process of the glass substrate can be compatible with smaller-sized LED chips, which not only reduces the cost of a single Micro-LED, but also reserves space for achieving higher pixel density.

Chenxian Optoelectronics has overcome the four major difficulties in Micro-LED displays one by one

Although TFT-based Micro-LED has many advantages in theory, the mass production process of large-size spliced ​​displays still needs to face four core technical difficulties: poor display uniformity, frequent bad pixels, weak seams, and split-viewing angles. In response to these problems, Chenxian Optoelectronics has provided systematic solutions.

Regarding the primary problem of image quality uniformity, since the current uniformity of incoming LED wafers can often only reach about 60%, and the wavelength error can even reach more than 12nm, if not dealt with, the LED display will have a blocky Mura phenomenon with obvious uneven brightness.

To this end, Chenxian Optoelectronics has pioneered the world's first technical solution that combines hybrid Bin (Vistar Micro Binning) and digital correction (Demura). The wavelength, brightness and appearance data of each LED are obtained through a high-speed detection system, and the self-developed AI algorithm is used to rearrange and combine the chips to ensure visual consistency between adjacent pixels. This solution not only increases the LED utilization rate from the original 40% to 80%, reduces the chip cost by about 50%, but also improves the brightness uniformity of the final product to more than 98%.

In solving the problem of frequent screen bad pixels, the accuracy and efficiency of mass transfer technology are the key. In the past, direct mass transfer often resulted in a large number of bad pixels, thereby increasing manufacturing costs.

Chenxian Optoelectronics adopts the mass transfer method of Known Good Die (KGD) and adopts multiple repair technologies to achieve a high level of yield of 99.995% in one transfer and 99.9999% after mass repair, and finally achieves the result of "0" dead pixels in shipped products.

In order to achieve truly seamless splicing, Chenxian Optoelectronics not only established its own splicing optical characterization standards and specifications, but also deeply optimized the edge pixel structure.

Through independently developed TFT backplane side wiring and double-sided process technology, the company has successfully eliminated the borders around the screen, making free splicing possible. With the special glass side wall protection process and packaging material optimization, the physical gap between the screens is controlled within 20 μm (about one-fifth of the diameter of a human hair), and the blackness of the seams is highly consistent with the display area, solving the problem of reflection or abnormal blackness at the seams of traditional splicing screens.

In addition, in order to solve the split-screen Mura problem caused by the difference in light shape of LED chips at different viewing angles, Chenxian Optoelectronics introduced the microlens array (MLA) structural design. Due to slight deviations in epitaxial thickness and etching control during the chip manufacturing process, the brightness difference of traditional solutions at large viewing angles is often greater than 10%.

Using the MLA structure to perform secondary correction of the luminous path, coupled with efficient astigmatism design, Chenxian Optoelectronics has successfully reduced the brightness difference under large viewing angles to less than 2%, ensuring that the color and brightness of the picture are highly consistent at different viewing positions.

Chenxian Optoelectronics released the dividends of Micro-LED technology in three steps

Thanks to the breakthroughs in the above-mentioned underlying technologies, Chenxian Optoelectronics was able to quickly switch from the Micro-LED technology research and development stage to the fast lane of industrialization layout, and formed a "three-step" stepped development strategy.

The first step of the strategy is to delve into the large-size commercial display market. Chenxian Optoelectronics chooses to start from demanding scenarios such as control and command centers, professional theaters and high-end retail. These fields have rigid demands for screen reliability, flatness and "zero seam" visual effects, and are relatively less price sensitive. They are the best release points for Micro-LED's advantages.

As the first large-size TFT-based Micro-LED mass production line in mainland China built by Chenxian Optoelectronics was successfully lit up in Chengdu at the end of 2024, the commercialization goal of this stage has entered an accelerated period. The total investment in the production line has reached 3 billion yuan. The planned production capacity will directly promote the transformation of Micro-LED from high-end customization to large-scale production. In 2025, Chenxian Optoelectronics successfully achieved mass production and shipment.

The second step in the strategy is to enter the high-end home theater market. Yao Zhibo pointed out that the demand for screens in the home environment tends to be eye protection, low energy consumption and maintenance-free. Chenxian Optoelectronics' AM driver has flicker-free characteristics and the glass substrate has extremely low heat generation, which exactly solves the pain point of the "grilled face" of traditional large screens and meets the pursuit of equipment comfort in home scenarios such as high-end villas and large flats. At present, the company has demonstrated the world's first 88-inch P0.5 and 135-inch P0.7 cabinet products that meet the golden ratio, preparing product reserves for entering the home market.

The third step of the strategy is to achieve full-scenario popularization and cross-border integration. In the future, Chenxian Optoelectronics will promote the penetration of Micro-LED technology into a broader consumer electronics market, such as automotive displays, retina-level wearable devices, etc. At the same time, Chenxian Optoelectronics will be committed to building Micro-LED into a platform technology, integrating micro-nano sensing devices on the panel through massive integration technology, and expanding its imagination in fields such as flexible terminals and naked-eye 3D.

Summary

Currently, Micro-LED technology is at the starting line of rapid growth, and Chenxian Optoelectronics has taken the lead in gaining an advantage in this display revolution through TFT-based Micro-LED technology.

Facing the future, Chenxian Optoelectronics will not only focus on its own parameter breakthroughs, but also build an industrial community including upstream and downstream equipment manufacturers, material manufacturers and terminal brands, and promote domestic Micro-LED to move into a new era of large-scale application through innovation-driven ecological linkage. (Text: LEDinside Irving)

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