How Plessey Semiconductors is redefining reality with the next generation of AR and microLED innovations
Working with world leaders in consumer technology, Plessey Semiconductors has built a reputation as one of the UK’s most innovative technology, design and manufacturing companies. Its mission is to deliver microLED display solutions that will change the way we interact with the world. MicroLEDs are widely regarded as the only recognized solution for the next generation of AR/MR wearable devices, automotive head-up displays and advanced consumer electronics, and Plessey is positioning itself at the center of that transformation.
When we last spoke to Keith Strickland in 2022, the company was still firmly in development mode, investing heavily in research and building capacity for the future. Three years on, he reflects on how far the business has come. “We’ve continued to develop our microLED and operational capabilities over the last few years, and we’ve invested significantly in our facilities to upgrade our hardware and modernize our production operations and systems,” he says. “We’ve added more tools and clean rooms within our facilities to ensure our capabilities align with customer needs, enabling us to better support long-term development requirements.”
That investment has not only enhanced manufacturing capacity, but also reshaped the environment in Plymouth. Modern, collaborative spaces have been created for both cross-functional and independent work, with breakout areas, quieter zones for focused activity, and a more contemporary design intended to attract the next generation of engineers. “The décor is much more modern, which we’re hoping will attract younger generations to enter our workforce, and the overall vibe is cooler and more welcoming,” Strickland adds.
This modernization reflects Plessey’s long-standing ability to reinvent itself. Following a management buyout in 2010, the company acquired the rights to GaN-on-Silicon technology through the purchase of Cambridge spin-out CamGaN. Initially, this was applied to solid-state lighting, horticultural products and medical sensing, but by 2016, Plessey had pivoted decisively to microLEDs, recognizing the opportunity to lead in what many believe is the most important display technology of the next decade. That focus soon delivered a string of world firsts. In 2019, the company demonstrated the emission of native green microLEDs without colour conversion, created the first HD 8-micron pixel display, pioneered GaN-on-Si wafer-to-wafer bonding, and delivered red InGaN LEDs on silicon. These achievements underscored Plessey’s reputation as one of the only organizations globally capable of moving microLEDs from lab research into commercial viability.
Today, Plessey is one of the very few businesses with true end-to-end manufacturing capability. From epitaxy and wafer growth through to bonding, packaging, testing and integration, everything is managed on site in Devon. This rare vertical integration allows for agility, quality control and fast innovation cycles that many competitors cannot match. That capability has already yielded significant results. In 2025, Plessey announced the world’s brightest red microLED display, achieving up to 6,000,000 nits at ultra-low power with pixels smaller than 5µm. Industry commentators immediately recognized it as a major milestone in overcoming one of AR’s biggest challenges: creating displays bright enough for daylight readability without compromising efficiency. It was hailed as a breakthrough that brings lightweight, commercially viable AR glasses a step closer to reality.
Behind these advances is a workforce that has more than doubled in size in recent years, growing from around 120 people in 2020 to more than 270 today. Apprenticeships, graduate recruitment and continuous training have all been expanded to ensure Plessey plays a role in securing the UK’s semiconductor skills base. The company’s commitment to its people is also reflected in its collaboration with Toyota, which began in 2023. Determined to build a culture of operational excellence, Plessey worked with Toyota to embed lean manufacturing principles across its operations. Employees undertook six-week customized training courses covering lean, Kaizen and structured problem-solving. The program quickly delivered higher yields, fewer bottlenecks and improved productivity, but the most significant change was cultural. “Toyota taught us more than efficiency,” Strickland reflects. “It gave our people confidence, the ability and permission to improve what they do every day.”
While AR and VR remain Plessey’s core focus, the opportunities for its technology go much further. Automotive head-up displays and premium consumer
electronics are immediate areas of expansion, but one of the most exciting frontiers is optical computing. By leveraging many of the same processes used in microLED fabrication, there is a real opportunity to develop processors that use light rather than electricity to handle data. This approach could unlock dramatic improvements in speed, efficiency and cooling, offering transformational benefits for AI and high-performance computing and Plessey is positioning itself to play a role in making that future a reality.
In August 2025, the company entered a new chapter with its acquisition by Haylo Labs, a venture operator dedicated to catalyzing and accelerating the global microLED ecosystem. The acquisition brings fresh investment, with Haylo committing more than £100 million over the next five years to expand Plessey’s capacity, double the workforce by 2034 and accelerate the company’s move from innovation to mass production. For Haylo, the acquisition is about continuity as well as growth, building on Plessey’s formidable heritage while positioning it for global leadership.
David Hayes, Co-Founder of Haylo Labs and now CEO of Plessey, describes it as a defining moment: “Plessey has long been one of the UK’s most important semiconductor companies. With Haylo’s investment and support, we can accelerate growth, broaden the customer base, and move from niche innovation to global mass production.”
The acquisition comes at a pivotal time. The international microLED market is forecast to grow from £2.7 billion in 2024 to more than £592 billion by 2034, driven by demand in AR/VR, automotive, consumer electronics and optical computing. With its unique combination of end-to-end manufacturing expertise, highly skilled workforce and world-leading intellectual property, Plessey is strongly positioned to capture a leading share of that growth.
As Hayes concludes: “We’re not just scaling a factory, we’re building the hardware foundation for the next era of computing. Plymouth has a proud heritage of innovation and manufacturing, and with Plessey we’re ensuring it also has a bold future.”