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The Future of Display Technology: Rayleigh Vision Intelligence's Contribution to Lowering Micro LED Costs
Would you be willing to pay around 30,000 USD for a TV with high brightness, high saturation, and excellent picture quality? This is the challenge facing Micro LED displays today: while the technology is impressive, the price is simply too high.
Micro LED is 30 times brighter than OLED, with higher saturation and lower power consumption. It shrinks traditional LEDs into tiny bulbs smaller than a human hair to form a display, without needing a backlight. This allows it to show clear images even in bright light, with vivid, rich, and detailed visuals. But what makes Micro LED so expensive? The key issue is the difficulty of mass production.
To create a Micro LED display, millions of chips smaller than a human hair need to be placed precisely into position. This process, known as "mass transfer," is both complex and costly, which is why Micro LED technology is not yet widespread.
Currently, only a few manufacturers, such as Samsung, have released high-end commercial Micro LED displays. However, their high price tags, make it difficult for them to reach the average consumer. The only way to make mass production feasible and ultimately lower the price is to significantly improve the speed and precision of traditional transfer technologies.
AI brings a ray of hope for Micro LED mass production. Rayleigh Vision Intelligence, which was involved in the development of Apple's Vision Pro and has years of experience in both academia and industry, has chosen to focus on using AI to optimize the most challenging aspect of the technology—mass transfer—improving production yield.
Rayleigh Vision Intelligence: 3 Key Technological Strengths
The mass transfer challenge is a major barrier to the widespread adoption of Micro LED. Rayleigh Vision Intelligence has identified three key bottlenecks: defects in the chips themselves, damage during the mass transfer process, and chip repairs after transfer. To address these, they’ve proposed an AI algorithm-based solution.
"Defects are unavoidable during chip production. Even with advanced processes, wafers can still experience color unevenness due to temperature variations," said Jr-Hau He , the founder of Rayleigh Vision Intelligence. A Micro LED display contains 13 million or more tiny chips, and making them flawless is extremely costly.
Rayleigh Vision Intelligence took a different approach: instead of pursuing "zero defects" for perfect chips, they chose to use AI to find a way to coexist with imperfections.
They utilize AI technology to evenly distribute chips with slight color differences across the screen, adjusting the originally uneven distribution of defects into a state more acceptable to the human eye. It's like spreading different-colored candies evenly on a table — even if each color has slight variations, the overall appearance remains consistent.
But the challenge doesn’t stop there. When transferring millions of LED chips at once, some chips inevitably get damaged. Therefore, controlling the yield becomes crucial. Rayleigh Vision Intelligence's AI acts like a skilled restorer, quickly identifying damaged chips, removing them with a laser, and replacing them with new ones. This process is akin to repairing a delicate mosaic.
"Our algorithm can precisely control the movement of the laser beam, effectively clearing multiple defects at once," explained co-founder Sam Ho. Compared to the traditional method of inspecting each chip individually, which requires hundreds of adjustments to complete, their team uses the algorithm to plan the optimal path, reducing alignment steps to under 100. This boosts yield and naturally lowers costs.
To accelerate market expansion, Rayleigh Vision Intelligence also showcased stacked Micro LED chips at this year’s CES (Consumer Electronics Show). These stacked chips allow for more LEDs in the same area, enhancing brightness and reducing power consumption.
This technology is not just for TV screens or automotive displays. "For example, AR/VR devices place a high emphasis on clarity and battery life, so stacking technology is essential," said Sam Ho. He believes this will be the key to mass-producing AR/VR devices, while also opening doors to previously unreachable potential customers, including automotive manufacturers, medical device companies, and even applications in the biotechnology field.
In the three years since its founding, the team has already partnered with over 10 upstream equipment and material suppliers in the display industry. However, the team also stated that, in the short term, they will focus on the automotive and TV display markets, with their long-term goal being AR/VR devices. Jr-Hau He explained, "Given the current market acceptance, the automotive and TV markets are easier to enter."
In addition to displays, the team is also targeting the potential development of Micro LED in the silicon photonics industry.
"Silicon photonics is a vast industry that requires collaboration from companies in various fields, such as IC design and light sources," Jr-Hau He explained. Since silicon photonics transmits data through light on a chip, the high brightness of Micro LED is expected to replace traditional laser light sources, making it an ideal light source for silicon photonics chips.
Currently, the company has obtained more than 30 patents, including key technologies that have not yet been publicly disclosed. In addition to software licensing, they also plan to integrate both software and hardware for sales and provide ongoing software update services.
Partners Launch Business, Using AI to Revolutionize Micro LED Mass Production
Rayleigh Vision Intelligence was co-founded by Jr-Hau He and Sam Ho. The two partners have complementary backgrounds—one in academia and the other in industry.
Jr-Hau He, the founder of Rayleigh Vision Intelligence, holds a Ph.D. from Tsinghua University and used to teach at National Taiwan University, specializing in light-emitting materials and processing research. For him, entrepreneurship and academic research are two very different worlds. "At university, we focused on publishing top-tier papers, but in business, our focus is on selling products," he says. He has always wanted to make a change and turn his research into real-world applications. "At some point, I just felt the need to do something different."
After closely watching the Micro LED industry, the brothers realized that the challenge of mass production was a major barrier to its growth. This insight led them to develop an AI-driven solution to tackle the problem.
"The world has changed. In the future, companies that understand AI will outpace those that don't," says Sam Ho. With nearly 20 years of industry experience, including working on Apple's Vision Pro's imaging technology, he believes that the traditional manufacturing processes, which focus too much on perfection, are only increasing costs.
Interestingly, Rayleigh Vision Intelligence uses a laser-based mass transfer technology, which is different from the electromagnetic adhesion technology route that Apple once tried and eventually abandoned. Sam Ho explains that Apple gave up because controlling the yield was difficult. "Many steps had a yield close to zero, making mass production impossible." However, with their experience from working at Apple and expertise in AI technology, they are confident they can overcome this challenge. "Because Apple gave up, we believe now is a great time to tackle it."
To achieve this, the brothers built a 23-person R&D team. Unlike traditional Micro LED companies, Rayleigh Vision Intelligence has an equal number of software and hardware developers. "Except for myself, the rest of the team members mainly come from the industry," says Jr-Hau He . This team composition allows them to balance academic innovation with industrial practicality.
However, the entrepreneurial journey has not been without challenges. Jr-Hau He admits that talent recruitment has always been their biggest challenge. Starting a business felt like jumping out of their comfort zone into an entirely new field. From working with different suppliers and communicating with people to learning about new things, it has all been a learning curve, and they have inevitably faced skepticism. "But being doubted has actually been a source of motivation because whatever we do, it always surprises people."
As for their future plans, Rayleigh Vision Intelligence is looking to raise funds in mid-year, with a focus on upstream equipment suppliers. They will continue developing new applications as well.
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