Thin and flexible photonic sensor foils are proposed, fabricated, and tested as a promising alternative for monitoring composite structures. Sensor foils are implemented using two different optical polymers and as such optimized for multi‐axial sensing and embedding within composite materials, respectively. It is first shown that those sensor foils allow multi‐axial strain sensing by multiplexing a multitude of Bragg grating sensors in a rosette configuration. Secondly, those sensors can be realized in very thin foils (down to 50 µm) making them suitable for embedding in composite materials during their production. This is proven by visually inspecting and by testing the functionality of the embedded sensors. Finally, owing to their low Young's modulus and flexibility, polymer sensor foils can be bent to small curvature radii and withstand large elongations. Herein, the sensors are bent down to a radius of 11 mm, and elongated by 1.4% without losing functionality.

Thin and flexible sensor foils are very suitable for unobtrusive integration with mechanical structures and allow monitoring for example strain and temperature while minimally interfering with the operation of those structures. Electrical strain gages have long been used for this purpose, but optical strain sensors based on Bragg gratings are gaining importance because of their improved accuracy, insusceptibility to electromagnetic interference, and multiplexing capability, thereby drastically reducing the amount of interconnection cables required. This paper reports on thin polymer sensor foils that can be used as photonic strain gage or temperature sensors, using several Bragg grating sensors multiplexed in a single polymer waveguide. Compared to commercially available optical fibers with Bragg grating sensors, our planar approach allows fabricating multiple, closely spaced sensors in well-defined directions in the same plane realizing photonic strain gage rosettes. While most of the reported Bragg grating sensors operate around a wavelength of 1550 nm, the sensors in the current paper operate around a wavelength of 850 nm, where the material losses are the lowest. This was accomplished by imprinting gratings with pitches 280 nm, 285 nm, and 290 nm at the core-cladding interface of an imprinted single mode waveguide with cross-sectional dimensions 3 × 3 µm2. We show that it is possible to realize high-quality imprinted single mode waveguides, with gratings, having only a very thin residual layer which is important to limit bend losses or cross-talk with neighboring waveguides. The strain and temperature sensitivity of the Bragg grating sensors was found to be 0.85 pm/µε and −150 pm/°C, respectively. These values correspond well with those of previously reported sensors based on the same materials but operating around 1550 nm, taking into account that sensitivity scales with the wavelength.

A novel platform based on evanescent wave sensing in the 6.5 to 7.5 µm wavelength range is presented with the example of toluene detection in an aqueous solution. The overall sensing platform consists of a germanium-on-silicon waveguide with a functionalized mesoporous silica cladding and integrated microlenses for alignment-tolerant backside optical interfacing with a tunable laser spectrometer. Hydrophobic functionalization of the mesoporous cladding allows enrichment of apolar analyte molecules and prevents strong interaction of water with the evanescent wave. The sensing performance was evaluated for aqueous toluene standards resulting in a limit of detection of 7 ppm. Recorded adsorption/desorption profiles followed Freundlich adsorption isotherms with rapid equilibration and resulting sensor response times of a few seconds. This indicates that continuous monitoring of contaminants in water is possible. A significant increase in LOD can be expected by likely improvements to the spectrometer noise floor which, expressed as a relative standard deviation of 100% lines, is currently in the range of 10 −2 A.U.

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Currently, most widely tunable lasers rely on an external diffraction grating to tune the laser wavelength. In this paper we present the realization of a chip-scale Vernier tunable racetrack resonator filter on the Ge-on-SOI waveguide platform that allows for wide tuning (108 nm free spectral range) in the 5 µm wavelength range without any moving parts. The fabricated racetrack resonators have a loaded Q-factor of 20000, resulting in a side-peak suppression of more than 20 dB, which is more than sufficient for wavelength selection in an external cavity laser.

Directly interfacing a photonic integrated circuit allows at best an alignment tolerance of a few micrometer due to the small dimensions of optical (coupling) features on chip, but when using microlenses integrated on the substrate-side, alignment tolerances for interfacing the chips can greatly be relaxed. This is demonstrated on a 750 μm thick chip with standard grating couplers (operation wavelength around 1550 nm). Low roughness silicon microlenses were realized by transferring reflowed photoresist into the silicon substrate using reactive ion etching. The microlens allows interfacing the chip from the backside with an expanded beam, drastically increasing lateral alignment tolerances. A 1 dB alignment tolerance of ±8 μm and ±11 μm (along and perpendicular to the grating coupler direction, respectively) was experimentally found when a 40 μm mode field diameter beam was used at the input.

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This paper demonstrates that epoxy-based single mode polymer waveguides with Bragg gratings can be realized in very thin (down to 50 micron) polymer foils which are suitable for strain sensing when integrated inside glass fiber reinforced polymer composite materials. The single mode waveguides were fabricated using laser direct-write lithography and the gratings were realized using nanoimprint lithography. These steps were performed on a temporary rigid carrier substrate and afterwards the functional layers were released yielding the thin, flexible sensor foils which can be laser-cut to the required dimensions. The Bragg grating-based polymer waveguide sensor foils were characterized before and after embedding into the composite. As expected, there was a blue shift in the reflection spectrum because of residual strain due to the embedding process. However, the quality of the signal did not degrade after embedding, both for 50 and 100 micron thick sensor foils. Finally, the sensitivity to strain of the embedded sensors was determined using a tensile test and found to be about 1 pm / microstrain.