The field of flexible, thin-film electronics is gaining traction as an alternative to conventional silicon chips. This technology, driven by thin-film transistors (TFTs), has the potential to revolutionize various applications, from wearable healthcare patches to bendable displays. However, the mass production of TFTs is currently limited to integration in displays for smartphones, laptops, and smart TVs. Chip designers are eager to explore innovative uses for TFTs, but lack the resources to do so.
To address this issue, researchers at KU Leuven and imec have proposed adopting the foundry business model from the conventional semiconductor industry. In this model, large fabrication plants focus on mass producing chips on silicon wafers, which are then used by companies to design specific applications. By applying this model to the field of flexible electronics, researchers believe that innovation can be accelerated and a wider range of applications can be explored.
The research group at KU Leuven developed a TFT-based microprocessor, the iconic MOS 6502, and had it produced in two separate foundries using different TFT technologies. The chips were manufactured on substrates alongside other projects in a multi-project approach, allowing for on-demand production of different chips. This approach enables flexibility in chip design and manufacturing, similar to the conventional chip industry.
The TFT-based microprocessor developed by the research group is less than 30 micrometers thick, making it ideal for medical applications such as wearable patches for monitoring heart and muscle conditions. These ultra-thin wearables offer a more comfortable and seamless experience compared to patches with silicon-based chips, which can feel bulky and uncomfortable. While the performance of the 6502 microprocessor may not be comparable to modern chips, the research highlights the potential for designing flexible chips in a multi-project approach.
Overall, the findings from this research support the idea that flexible, thin-film electronics can benefit from a foundry business model similar to that of the conventional chip industry. By enabling innovative applications and accelerating development in the field, this approach has the potential to unlock new possibilities for TFT technology. While these flexible chips may not compete with silicon-based chips, they can stimulate and encourage innovation in the growing field of flexible electronics.
