Optical data communication is increasingly interesting for many applications in industrial processes. Therefore mass production is required to meet the requested price and lot sizes. Polymer optical waveguides show great promises to comply with price requirements while providing sufficient optical quality for short range data transmission. A high efficient fabrication technology using polymer materials could be able to create the essential backbone for 3D-optical data transmission in the future. The approach for high efficient fabrication technology of micro optics described in this paper is based on a self-assembly effect of fluids on preconditioned 3D-thermoformed polymer foils. Adjusting the surface energy on certain areas on the flexible substrate by flexographic printing mechanism is presented in this paper. With this technique conditioning lines made of silicone containing UV-varnish are printed on top of the foils and create gaps with the exposed substrate material in between. Subsequent fabrication processes are selected whether the preconditioned foil is coated with acrylate containing waveguide material prior or after the thermoforming process. Due to the different surface energy this material tends to dewet from the conditioning lines. It acts like regional barriers and sets the width of the arising waveguides. With this fabrication technology it is possible to produce multiple waveguides with a single coating process. The relevant printing process parameters that affect the quality of the generated waveguides are discussed and results of the produced waveguides with width ranging from 10 to 300 µm are shown.
The optical data transfer is considered as the future of signal transfer due to its various advantages compared to conventional copper-based technologies. The Aerosol Jet Printing (AJP) technology offers the opportunity to print materials with high viscosities, such as liquid transparent polymer adhesives (epoxy resins), on almost any possible substrate material and even in third dimension. This paper introduces a new flexible and comparatively cost-effective way of generating polymer optical waveguides through AJP.Furthermore, the conditioning of the substrate material and the printing process of planar waveguides are presented. In the first step, two lines with hydrophobic behavior are applied on foil material (PMMA, PVC, PI) by using a flexographic printing machine. These silicone based patterns containing functional polymer form barriers for the core material due to their low surface energy after curing. In the second step, the core material (liquid polymer, varnish) is printed between the barrier lines. Because of the hydrophobic behavior of the lines, the contact angle between the substrate surface and the liquid core material is increased which yields to higher aspect ratio. The distance between the barrier lines is at least 100 µm, which defines the width of the waveguide. The minimum height of the core shall be 50 µm. After UV-curing of the core polymer, the cladding material is printed on the top. This is also applied by using the AJP technology. Various tests were performed to achieve the optimal surface properties for adequate adhesion and machine process parameters.
We have created high-precision, miniaturized, substrate-free filters, based on ion beam sputtering on a sacrificial substrate. The sacrificial layer is cost efficient and environmentally friendly and can be dissolved using only water. We demonstrate an improved performance compared to filters on thin polymer layers from the same coating run. With these filters, a single-element coarse wavelength division multiplexing transmitting device for telecommunication applications can be realized by inserting the filter between fiber ends.
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