Making and using compacted pellets for OLED displays

A method of forming a compacted pellet of organic materials adaptable for making an organic layer on a structure which will form part of an OLED display, includes providing a sublimable organic material in a powder form; providing a thermally insulating and non-sublimable inorganic material in a powder form; forming a mixture of the sublimable organic powder and thermally insulating and non-sublimable inorganic powder; placing such mixture into a die and using two punches, a lower and an upper punch, to apply sufficient pressure to the mixture to cause the mixture of powders to consolidate into a solid pellet; applying heat to the die during or prior to applying pressure by the opposing punches to aid in causing the mixture of powders to consolidate into a solid compacted pellet, and removing the pellet from the die.