Low-cost fabrication of form-birefringent quarter-wave plates

An extensive study of the single-step replication of form-birefringent quarter-wave plates is presented. Using rigorous diffraction theory, the fabrication parameters and tolerances are carefully studied in order to obtain ideal conditions for successful replication. The design considerations are then applied to fabricate a master element by electron-beam lithography, and to replicate quarter-wave plates using the UV-moulding process. The measurements show that the replicas behave as high-performance quarter-wave plates for the design wavelength.