GE is working since 2003 on roll-to-roll OLED printing (of flexible and transparent OLED lighting panels). Dr Yan from GE says that in 2007, they had fairly high defects, around 65% yield. Today GE says that their yield is between 90%-95%.
One of the biggest issues GE is tackling is the flexible barrier layer to protect the OLED devices. GE has developed an "Ultra High Barrier" (UHB) by plasma enhanced chemical vapor deposition. The performance that has been achieved is low 10-5g/m2/day, with good transparency and adhesion.
Dr Yan says that roll-to-roll organic printing is real, and OLED lighting is getting closer. OLEDs are still around 15 times more expansive than conventional lighting, but the price will drop in time, and OLEDs will get cheaper than LEDs because of roll-to-roll printing and potentially cheaper materials.
IDTechEx believes that it will take between 5 to 10 years for OLEDs to become cost effective. But even before that OLEDs can be used in high-value products and niches.