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Patterned deposition of polymer light-emitting diode (PLED) pixels is a challenge for electronic display applications. PLEDs have additional problems requiring solvent orthogonality of different materials in adjacent layers. We present the fabrication of a PLED pixel by the sequential deposition of two different layers with laser-induced forward transfer (LIFT), a "dry" deposition technique. This novel use of LIFT has been compared to "normal" LIFT, where all the layers are transferred in a single step, and a conventional PLED fabrication process. For the sequential LIFT, a 50-nm film of an alcohol soluble polyfluorene (PFN) is transferred onto a receiver with a transparent anode, before an aluminum cathode is transferred on top Both steps use a triazene polymer dynamic release layer and are performed in a medium vacuum (1 mbar) across a 15 mu m gap. The rough morphologies of the single layer PFN pixels and the PLED device characteristics have been investigated and compared to both bilayer Al/PFN pixels fabricated by normal LIFT and conventionally fabricated devices. The functionality of the sequential LIFT pixels (0.003 cd/A, up to 200 mA/cm(2), at 30-40 V) demonstrates the suitability of LIFT for sequential patterned printing of different thin-film layers.

Laser-induced forward transfer (LIFT) has already been used to fabricate various types of organic light-emitting diodes (OLEDs), and the process itself has been optimised and refined considerably since OLED pixels were first demonstrated. In particular, a dynamic release layer (DRL) of triazene polymer has been used, the environmental pressure has been reduced down to a medium vacuum, and the donor receiver gap has been controlled with the use of spacers. Insight into the LIFT process's effect upon OLED pixel performance is presented here, obtained through optimisation of three-colour polyfluorene-based OLEDs. A marked dependence of the pixel morphology quality on the cathode metal is observed, and the laser transfer fluence dependence is also analysed. The pixel device performances are compared to conventionally fabricated devices, and cathode effects have been looked at in detail. The silver cathode pixels show more heterogeneous pixel morphologies, and a correspondingly poorer efficiency characteristics. The aluminium cathode pixels have greater green electroluminescent emission than both the silver cathode pixels and the conventionally fabricated aluminium devices, and the green emission has a fluence dependence for silver cathode pixels. (C) 2012 Elsevier B.V. All rights reserved.