Lessons Learned in Roll-to-Part Manufacturing of Consumer Electronics

Kent Displays, Inc. (KDI), a global leader in integrating flexible optics with flexible electronics to scale production of consumer products via “R2X” (e.g., roll-to-roll, roll-to-part, roll-to-consumer, roll-to-...), successfully overcame a variety of manufacturing challenges creating products with unique requirements that necessitate production in cleanrooms at high volume. Using diverse research and development, advanced manufacturing, and product development case studies, this presentation highlights lessons learned from commercialization of high-value flexible optical devices. With a proven approach to minimizing risks when developing new products using flexible polymer film for optical applications with tight tolerances and minimizing particle contamination that must integrate seamlessly with liquid crystal displays and electronics, the presenter will share the struggles and triumphs of diverse engineers and industrial scientists who deliver rapid prototyping through KDI Technical Services to customers in multiple industries with low waste meeting sustainability goals. The case studies form the basis for a methodology that can aid the greater flexible electronics community.