Fabrication of optical components with nm-to mm-scale critical features using three-dimensional direct laser writing

A powerful fabrication strategy based on three-dimensional direct laser writing for the rapid prototyping of opto-mechanical components with critical features ranging from several hundred nm to a few mm is demonstrated here. As an example, a simple optical fiber connector with optical and mechanical guides as well as integrated micro-optical elements with nano-structured surfaces is designed and fabricated. In contrast to established three-dimensional direct laser writing, two different polymers are combined in the fabrication process in order to achieve a drastic reduction in fabrication time by substantially reducing the 'optical tool path'. A good agreement between the as-fabricated connector and nominal dimensions has been obtained. The developed approach allows the rapid proto-Typing of optomechanical components with multi-scale critical features. It is, therefore, envisioned to substantially accelerate the development cycle by integrating functional mechanical and optical elements in a single component.