3D-nanoprinted vertical coupler using hybrid lithography for optical redistribution applications.

Area of Science:

• Photonics and Optical Engineering
• Materials Science and Engineering
• Microfabrication Technologies

Background:

• Optical redistribution is crucial for advanced 3D photonic systems.
• Traditional vertical couplers often require complex metallization or air cavities.
• Developing integrated, high-performance optical interconnects remains a significant challenge.

Purpose of the Study:

• To demonstrate a novel polymeric vertical coupler for optical redistribution applications.
• To develop a scalable and cost-effective fabrication method for vertical couplers.
• To achieve high coupling efficiency in an all-solid total internal reflection (TIR) mirror design.

Main Methods:

• Hybrid-lithography combining ultraviolet (UV) lithography and two-photon polymerization (TPP).
• Fabrication of a planar optical redistribution layer (ORDL) using UV lithography.
• Creation of vertical coupling micromirrors via TPP for an all-solid TIR mirror.

Main Results:

• Achieved an all-solid TIR mirror by leveraging high refractive-index contrast, eliminating metallization.
• Theoretical coupling efficiencies of 89.4% (unsupported) and 81.6% (supported).
• Experimental coupling loss of approximately 3.3 dB at 1310 nm telecommunication wavelength.

Conclusions:

• The hybrid-lithography approach offers a scalable and cost-effective method for vertical coupler fabrication.
• The all-solid TIR mirror design simplifies integration into 3D photonic systems.
• This technology enables high-performance vertical interconnects for advanced optical systems.