Methods and apparatus for fabricating and cutting flexible glass and polymer composite structures

A method, comprising:

• sourcing an ultra-thin glass sheet having first and second opposing major surfaces and perimeter edges therebetween, the glass sheet having a thickness between the first and second surfaces of less than about 300 microns;
• adhering at least one polymer layer directly or indirectly to at least one of the first and second surfaces of the glass sheet to form a laminated structure, wherein a thickness of the at least one polymer layer is between about 3-10 mils;
• and
• cutting the laminated structure using at least one of the following techniques:
• shear cutting, burst cutting, slit cutting, and crush cutting,
• wherein the cutting step produces at least one cut edge having an edge characteristic in which a plurality of lateral cracks run from the cut edge into the glass sheet, and wherein the plurality of cracks penetrate no further than about 600 microns.