Manufacturing LEDs on Large Diameter Substrates:What's The Holdup?

A transition to 6- or 8-in wafers will ultimately deliver lower-cost LEDs, although as Marcus Weddle discusses, the industry must overcome technical and logistical challenges.

In the search to cut the costs of manufacturing LEDs, switching to large diameter (6-8-in, 150-200-mm) substrates is often brought up as a key solution. In fact, it is mentioned so often that one might assume a mass transition to large diameter has already occurred. Such a transition has been slow to happen due to both technical and logistical challenges. But as we will discuss, the advantages will ultimately be significant enough that the LED manufacturers will move to larger substrates, reduce component costs, and further accelerate the adoption of solid-state lighting (SSL).

Analysts are predicting that for 2013, less than 20% of production will be on 6-in wafers, with 8-in not even showing up in significant numbers this year. Even three years from now, large diameter is only predicted to be breaking the halfway point of all substrate sizes.

This may come as a surprise because the demand for large diameter should be very high – it has often been cited as a fundamental cost saver to drive down LED chip prices. With the industry-wide search to drive down cost significantly, and large diameter seen as a key way to accomplish this, why aren’t more chip producers making this switch?

To answer this question, we will look at three areas. First, what are the true benefits of large diameter? Second, if the benefits are truly great, then why aren’t more manufacturers switching? Finally, we’ll look at some of the potential disruptions that might bring quicker large diameter adoption, such as c-axis CHES (controlled heat extraction system) technology – along with the prospect of 8-inch substrates.


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