LG has unveiled FLiPP, a new manufacturing method designed to replace the FMM process used for over a decade. This mask-less approach aims to significantly improve brightness and durability across a wide range of screen sizes.
The physical weight limits of the decade-old FMM process
For more than ten years, LG has utilized Fine Metal Masks (FMM) as its primary method for manufacturing OLED panels. This process involves creating millions of micron-sized holes in a thin metal stencil to guide red, green, and blue light-emitting vapors onto a glass substrate. While effective for years, the technique has reached a physical ceiling.
As display sizes grow, the sheer mass of the metal mask becomes a liability. The report indicates that the weight of these masks can cause the center of larger panels to become slightly misshapen. This deformation can compromise the accuracy of RGB pixel application, making it increasingly difficult to maintain high-resolution quality on massive screens. Furthermore, every change in resolution or panel size requires a completely new, expensive mask, adding significant time and cost to the production cycle.
Boosting brightness by 1 .6x with 55% more pixel coverage
LG's new FLiPP technology, which stands for FMM-Less innovative Pixel Patterning, seeks to bypass these physical hurdles by removing the metal mask entirely. Instead of relying on a physical stencil, LG will use photolithography to create precise patterns. The process involves adding light-emitting vapors in a specific sequence to fill as much space as possible with tightly packed RGB pixels.
According to LG, this shift allows for a 55% increase in the amount of glass covered by RGB pixels compared to the traditional FMM method. This increased density is expected to yield massive performance gains. Specifically, LG claims that FLiPP-manufactured panels will be 1.6 times brighter and will last 2.4 times longer than current models. Additionally, the company expects these new displays to be more efficient, utilizing 13% less power than their FMM-based predecessors.
A 2027 rollout for devices ranging from smartwatches to 100-inch TVs
The versatility of the FLiPP process suggests a wide-reaching impact across the entire consumer electronics spectrum. LG has stated that the technology can be applied to panels ranging from 1 inch to 100 inches, making it suitable for everything from tiny smartwatches to massive home theater televisions. This flexibility also extends to specialized hardware, such as tablets, computer monitors, and virtual or augmented reality headsets.
Beyond just size, the removal of the heavy metal mask opens the door for new form factors. LG suggests that the technology could support non-standard aspect ratios and even improve the quality of curved screens. By creating brighter curved displays, the company hopes to reduce the glare and viewing-comfort issues that currently affect some high-end curved OLED models. The first consumer products built with this new method are expected to arrive in late 2027.
The competitive stakes for LG's 50% market share
While the technical advantages of FLiPP are substantial, the transition involves significant unknowns. The source does not detail the capital expenditure required to move from FMM to a photolithography-based system, which is a major shift in manufacturing infrastructure. Whether the cost savings from eliminating masks will offset the initial investment in new equipment remains a critical question for investors.
Furthermore, the timing of the 2027 rollout leaves a window for competitors to react. LG currently holds nearly half of the global OLED TV market as of 2025, and this technological leap could help solidify that dominance. however, it is still unclear if other major display manufacturers will attempt to develop their own mask-less alternatives or if LG will successfully establish FLiPP as the new industry standard.
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