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    Manufacturing multilayer diffractive optical elements (MLDOEs) demands precision. This study reveals that period width errors significantly impact MLDOE diffraction efficiency, a factor underestimated by scalar diffraction methods.

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    Area of Science:

    • Optics and Photonics
    • Optical Engineering
    • Nanotechnology

    Background:

    • Multilayer diffractive optical elements (MLDOEs) are crucial for high-efficiency hybrid optical systems.
    • Accurate MLDOE fabrication is essential for reliable performance.
    • Microstructure period width errors are critical manufacturing parameters.

    Purpose of the Study:

    • To analyze the impact of period width errors on MLDOE diffraction efficiency.
    • To compare rigorous electromagnetic methods with scalar diffraction methods for error analysis.
    • To provide a reliable method for controlling fabrication errors in MLDOEs.

    Main Methods:

    • Rigorous electromagnetic simulation.
    • Analysis of diffraction efficiency under varying period width errors.
    • Comparison with scalar diffraction theory predictions.

    Main Results:

    • Diffraction efficiency is highly sensitive to period width errors.
    • The effect of period width errors is underestimated by scalar diffraction methods.
    • Rigorous electromagnetic analysis provides a more accurate assessment.

    Conclusions:

    • Precise control of period width errors is vital for MLDOE fabrication.
    • Rigorous electromagnetic methods offer superior accuracy for MLDOE error analysis.
    • This research establishes a reliable framework for managing fabrication tolerances in MLDOEs.