Applications Development for Low-Cost Microjet Printing of Micro-Optics.

Abstract : A novel technology was developed for fabrication of refractive micro-optical elements by inkjet printing. It is ideally suited for many optoelectronic manufacturing applications, because it is a low-cost-(no masks plus an additive process), automated (data-driven), and non-contact process capable of in-situ printing of micro-optical interconnects directly onto photonic substrates and components. Optical materials, print heads and processes were developed for micro-depositing UV-curing optical epoxy formulations at high temperatures, in order to form microlenses and waveguides with dimensions down to 70 micrometers, which could withstand subsequent processing temperatures up to 200 deg C. Working with guidance from researchers at organizations such as Honeywell, Rockwell and Lawrence Livermore National Laboratories, capabilities were developed to address a wide range of next-generation photonics systems. These applications included: massively parallel, VLSI photonic switches; infrared communication systems; optical computing systems; telecom transceivers; and biochemical fiber optic sensors. The micro-optics printing capabilities achieved and demonstrated during this contract have led to follow-on, development contracts from Honeywell (DARPA-2yrs) and Nortel Networks for datacom and telecom applications, respectively.