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Sapphire is a robust and wear-resistant material. However, efficient and high-quality micromachining is still a challenge. This contribution demonstrates and discusses two novels, previously unreported approaches for femtosecond laser-based micromachining of rotational-symmetric sapphire workpieces, whereas both methods are in principal hybrids of laser scanning and laser turning or laser lathe. The first process, a combination of a sequential linear hatch pattern in parallel to the workpiece’s main axis with a defined incremental workpiece rotation, enables the fabrication of sapphire fibers with diameters of 50 µm over a length of 4.5 mm. Furthermore, sapphire specimens with a diameter of 25 µm over a length of 2 mm can be fabricated whereas an arithmetical mean height, i.e., Sa parameter, of 281 nm is achieved. The second process combines a constant workpiece feed and orthogonal scanning with incremental workpiece rotation. With this approach, workpiece length limitations of the first process are overcome and sapphire fibers with an average diameter of 90 µm over a length of 20 cm are manufactured. Again, the sapphire specimen exhibits a comparable surface roughness with an average Sa value of 249 nm over 20 cm. Based on the obtained results, the proposed manufacturing method paves an innovative and flexible, all laser-based way towards the fabrication or microstructuring of sapphire optical devices, and thus, a promising alternative to chemical processes.
This contribution quantifies the birefringence within injection-molded cyclic olefin copolymer plates and discusses its impact on the mechanical properties of the plates. It also focuses on the impact of birefringence on integrated waveguides and Bragg gratings and provides fabrication guidelines for such structures. The anisotropy in all three dimensions of the workpiece is examined by means of polarimetry and a prism coupler. It is found that the birefringence is inhomogenously distributed within the workpieces, whereas the maximum birefringence not only varies locally, but also depends on the observation direction. Overall, a maximum birefringence of 10 × 10−4 is found at the plate’s surface near the injection gate. The anisotropy then reduces exponentially towards the center of the workpiece and saturates at 1.8 × 10−4, in a depth of 0.4 mm. Thus, the birefringence strongly affects near-surface photonic structures. It is found that, depending on their orientation and the local birefringence of the substrate, waveguides and Bragg gratings fabricated with comparable parameters behave completely differently in terms of polarization-dependent optical attenuation, cross-sectional intensity distribution and Bragg reflection signal. For example, the support of the TM mode can vary between total loss and an optical attenuation of 0.9 dB × cm−1. In consequence, this study underlines the importance of quantifying the birefringent state of an injection-molded cyclic olefin copolymer workpiece if it is supposed to serve as a substrate for integrated photonic structures. The study furthermore demonstrates that birefringence effects can be omitted by burying the photonic structures deeper into the volume of the thermoplastic.
We demonstrate and discuss the integration of Bragg gratings in aerosol-jetted polymer optical waveguides, produced in the optical assembly and connection technology for component-integrated bus systems (OPTAVER) process. By using a femtosecond laser and adaptive beam shaping, an elliptical focal voxel generates different types of single pulse modification by nonlinear absorption in the waveguide material, which are arranged periodically to form Bragg gratings. Integration of a single grating structure or, alternatively, an array of Bragg grating structures in the multimode waveguide yields a pronounced reflection signal with typical multimodal properties, i.e., a number of reflection peaks with non-Gaussian shapes. However, the main wavelength of reflection, located around 1555 nm, is evaluable by means of an appropriate smoothing algorithm. When loaded by mechanical bending, a pronounced Bragg wavelength shift of this reflected peak up to 160 pm is detected. This demonstrates that the additively manufactured waveguides can be used not only for signal transmission but also as a sensor.
While sapphire is one of the most durable materials, its properties entail that high-precision machining, especially in the sub-millimeter regime, is still challenging. This contribution demonstrates and discusses novel femtosecond laser-based micromachining approaches for the fabrication of rotational-symmetric sapphire workpieces, specifically the generation of optical fibers by means of laser lathe of sapphire rods and the practical realization of windmill fibers. In addition, volume refractive index modification in planar sapphire substrates is presented to induce photonic crystal waveguides. The micromachined structures are comprehensively examined with respect to geometric fidelity, surface roughness, refractive index modification, and potential optical waveguiding properties. All micromachining approaches are done by means of frequency-doubled or frequency-tripled femtosecond laser radiation. Different laser optical setups including laser scanning head, spatial beam profilers including a spatial light modulator and axial rotatory movement of the specimen are employed for micro structuring and in-depth refractive index modifications. In particular for laser lathe, a sophisticated scanning pattern, in combination with an incremental axial rotatory movement of the specimen, allows for the precise diameter reduction of sapphire rods with 250 µm diameter to fibers with outer diameters of 25 µm. By supporting the workpiece with a V-groove fixture, multi-mode fibers with lengths up to 20 cm can be processed with an average surface roughness of 250 nm. Additionally, an adapted ablation scanning sequence enables the first practical demonstration of sapphire windmill fibers. Furthermore, using a spatial light modulator allows for the adaption of the laser propagation properties as to enable volume refractive index modifications with free-form arrangement. Hexagonal patterns of refractive index modifications surrounding a pristine waveguide core are fabricated and single-mode waveguiding at 1550 nm is verified. Finally, the possibility of integrating Bragg gratings into this photonic waveguide type is demonstrated
While Bragg grating-based optical devices have shown promising performances for pressure sensing applications, their sensitivity, especially in the low-pressure regime, is unsatisfying and needs to be optimized by elaborate designs, such as cantilevers or other extrinsic mechanical transducers. This contribution demonstrates and discusses a novel concept for optical pressure sensors based on polymer planar Bragg gratings. Waveguide and Bragg grating are fabricated underneath the surface of a temperature-stable and humidity-insensitive cyclic olefin copolymer substrate by means of a femtosecond laser. Based on the employed direct-writing procedure, in combination with adaptive, in-situ beam shaping with a spatial light modulator, writing depth, i.e., location of the photonic structures within the substrate, as well as Bragg grating periodicity and positioning can be deliberately chosen. Afterwards, the polymer substrate is post-processed with a high-precision micro mill, so a diaphragm comprising the integrated photonic structures is generated. The resulting diaphragm exhibits a thickness of 300 µm and a diameter of 10 mm. Finally, the optical sensor is packaged and sealed to form an air-filled gas pocket underneath the diaphragm. Deformations of the diaphragm by external pressure changes translate to strain variations along the waveguide axis and thus perturb the Bragg grating period. This leads to changes in the grating’s wavelength of main reflection, which can be evaluated in order to quantify the relative external pressure. With this straightforward optical sensor concept, pressure sensitivities up to 39 pm kPa-1, within relative pressures ranges from 78 kPa to 372 kPa, are achieved.
This article proposes and demonstrates a robust microstructure-based fiber-to-chip coupling scheme for planar Bragg grating devices. A polymer planar Bragg grating substrate is manufactured and microstructured by means of a micromilling process, while the respective photonic structures are generated by employing a sophisticated single-writing UV-exposure method. A stripped standard single mode fiber is inserted into the microstructure, which is filled with a UV-curable adhesive, and aligned with the integrated waveguide. After curing, final sensor assembly and thermal treatment, the proposed coupling scheme is capable of withstanding pressures up to 10 bar, at room temperature, and pressures up to 7.5 bar at an elevated temperature of 120 °C. Additionally, the coupling scheme is exceedingly robust towards tensile forces, limited only by the tensile strength of the employed single mode fiber. Due to its outstanding robustness, the coupling scheme enables the application of planar Bragg grating devices in harsh environments. This fact is underlined by integrating a microstructure-coupled photonic device into the center of a commercial-grade carbon fiber-reinforced polymer specimen. After its integration, the polymer-based Bragg grating sensor still exhibits a reflection peak with a dynamic range of 24 dB, and can thus be employed for sensing purposes.
This study demonstrates and discusses a novel approach for the fabrication and rapid prototyping of monolithic photonic platforms comprising a ridge-type waveguide with integrated sensing structures. First, the bulk injection-molded cyclic olefin copolymer substrates are micromilled in order to define the physical extension of the ridge structure. Cross-sections down to 30 × 30 µm2, exhibiting a mean surface roughness of 300 nm, are achieved with this process. Subsequently, UV radiation is used to modify the ridge structure’s refractive index, which leads to the formation of an optical waveguide. By employing a phase mask, it is possible to equip the photonic platform with a Bragg grating suitable for temperature measurements with a sensitivity of −5.1 pm K-1. Furthermore, an integrated Fabry-Pérot cavity, generated during the micromilling step as well, enables refractive index measurements with sensitivities up to 1154 nm RIU-1.
This contribution demonstrates and discusses electrically tunable polymer planar Bragg gratings based on bulk cyclic olefin copolymers. A lithographic single-writing-step method and femtosecond laser reductive sintering of copper(II) oxide nanoparticles are subsequently employed in order to generate buried photonic structures and copper conducting paths on top of the polymer substrate. This way, the necessary number of process steps for fabricating a planar polymer-based electro-optical device is greatly reduced. The response of a fully electrified grating structure follows temperature changes, induced by the copper conducting path, with sensitivities up to −31 pm K−1. Dilatometric measurements show that the specimen's behavior is correlated to the situationally reduced thermal expansion of the bulk polymer substrate. In consequence, the tuning response of the photonic platform follows a second order polynomial, whereas a direct current of 30 mA, which correlates to a power consumption of 18.3 mW, leads to a local temperature increase and a residual Bragg wavelength shift of 19.6 K and −547 pm, respectively. Moreover, the outstanding flexibility of the proposed fabrication concept is underlined by demonstrating alternative conducting path geometries, whereas one of the additional designs is adapted to control the spectral width of the Bragg grating's reflection peak.
This contribution reviews recent advancements, current research and possible applications of polymer planar Bragg grating (PPBG) sensors with a focus on the utilization of cyclic olefin copolymer (COC) substrates. COC-PPBGs can be handled and fabricated efficiently by employing a single writing step procedure which features simultaneous generation of waveguide and Bragg grating structure within an injection molded substrate. The resulting photonic structures exhibit an attenuation as low as 1.2 dB cm-1 and a reflectivity up to 99 %. The potential of COC-PPBGs for high-temperature applications is proven by demonstrating temperature measurements up to 160 °C. Moreover, it is possible to employ single PPBGs for multidimensional stress and strain sensing or even three-dimensional shape reconstruction. Due to their excellent properties, it is feasible to integrate COC-PPBGs into commercial-grade carbon fiber reinforced polymer workpieces for structural health monitoring. Furthermore, utilization of appropriate coatings enables functionalization of PPBGs for refractive index sensing and thus biochemical applications. Beside the fabrication and characterization of COC-based PPBGs, this contribution exemplifies and reviews such applications.
This contribution discusses the integration of polymer planar Bragg grating sensors (PPBG) into carbon fiber reinforced polymer (CFRP) components. For the first time, it is shown that PPBGs based on cyclic olefin copolymers can be integrated into commercial-grade composites, thereby withstanding the demanding production processes. Pre-impregnated fibers are stacked and partially modified to form a sensor pocket. Afterwards, the CFRP specimen containing the optical sensor is cured in a heated mechanical press for 2 hours at a pressure of 7 bar and a temperature of 120 °C. A subsequent evalutaion of the sensor signal shows a Bragg wavelength shift of 1236 pm and a decline in signal amplitude of -2 dB. Three-point flexural tests of the cured sample reveal a linear behavior of the sensor signal towards external loads. The determined sensitivity in dependence of the CFRP specimen's maximum central deflection is -112 pm/mm, while correlation to the applied force results in a sensitivity of -5 pm/N.
This contribution demonstrates the functionality of polymer planar Bragg grating (PPBG) sensors integrated into commercial-grade carbon fiber reinforced polymer (CFRP) components. Multiple CFRP specimens are generated by curing a stack of pre-impregnated fibers inside of a heated mechanical press, exposing the polymer sensor to a pressure of 7 bar and a temperature of 120 °C for 2 h. After integration, the sensor still exhibits a strong and evaluable signal. Subsequent flexural experiments reveal a linear response of the integrated sensor’s Bragg wavelength to the CFRP specimen’s maximum deflection. Additional findings demonstrate that the embedded PPBG can be used to detect plastic deformations of a CFRP workpiece, whereas a linear correlation of plastic deformation to the resulting Bragg signal offset is determined. A plausibility check of the obtained results is delivered by a comparison of three-point flexural experiments on bulk CFRP workpieces, without integrated sensors and additional specimens featuring external optical sensors affixed to their surface. It is found that PPBGs based on cyclic olefin copolymers are able to overcome the temperature-related limitations of traditional polymer-based optical sensors and can thus be directly integrated into commercial-grade composites during production.
We report on a femtosecond laser based fabrication technique that enables simultaneous single-step generation of optical waveguides and Bragg gratings inside bulk cyclic olefin copolymers. Due to the nonlinear absorption of focused and spatially modulated laser radiation with a wavelength of 514 nm and a pulse duration of 450 fs, a modification concluding a refractive index shift increase inside the substrate can be achieved. A sophisticated characterization of the generated waveguides by means of an elaborate cut-back method reveals a maximum attenuation of 3.2 dB/cm. Additionally, a Mach-Zehnder interferometer is used to examine the waveguide’s refractive index profile. The integrated Bragg grating structures exhibit reflectivities up to 95 % and a spectral full width at half maximum of 288 pm, at a Bragg wavelength of 1582 nm, whereas the grating period can be deliberately chosen by adapting the fabrication parameters. Thus, due to its increased flexibility and the resulting dispensability of cost-intensive phase masks, this method constitutes an especially promising fabrication process for polymer Bragg gratings inside of bulk materials.
We report on femtosecond laser direct writing of electrically conductive copper structures on transparent cyclic olefin copolymer based planar optical chips. The process is based on a laser-induced reduction of CuO nanoparticles dissolved in a water-soluble resin. Thus generated conductive copper structures are characterized with respect to their chemical composition and electrical resistivity. In addition, the application of ultrashort laser pulses enables a hybrid micromachining approach comprising ablation of polymer substrates and the fabrication of copper patterns in a single laser processing setup. A possible electro-optical application of this approach is demonstrated by employing the copper structures as an electro-thermal microheater in combination with a polymer planar optical Bragg grating sensor. This, in turn, highlights the potential of generating copious micro-opto-electro-mechanical polymer structures for numerous sensing applications ranging from Lab-on-Chip to environmental applications using the presented hybrid micromachining approach.
Hypersensitive H2 sensor based on polymer planar Bragg gratings coated with Pt-loaded WO3-SiO2
(2020)
This letter demonstrates a novel hydrogen sensor based on a polymer planar Bragg grating coated with Pt-loaded WO3-SiO2. The reflected Bragg signal shows a distinct peak splitting correlated to substrate anisotropies originating from the injection molding process. Especially at low H2 concentrations, both sensing peaks
exhibit an outstanding response to the heat generated by the exothermic reaction between hydrogen molecules and coating. Thereby, a hydrogen volume ratio of 50 ppm
leads to a Bragg wavelength shift of -37 pm, which yields an outstandingly low detection limit of only 5 ppm H2 in air. Thus, functionalized polymer planar Bragg gratings are eminently suitable for H2 leak detection applications.
In this study, we report on the integration of microfluidic channels and optical components by focusing femtosecond laser radiation inside transparent cyclic olefin copolymer (COC) bulk material. An internal localized material modification is triggered based on nonlinear absorption of the laser radiation's high intensities inside the focal volume. The size and shape of the three-dimensional internal modification are controlled by using an adaptive beam shaping setup. The irradiated areas show a positive refractive index shift and can be used as Type I internal optical waveguides. Furthermore, precise control of the spatial pulse-to-pulse distance in combination with a suitable beam profile enables the integration of functional photonic elements, e.g., Bragg gratings, into the waveguide. Thus, it also enables the generation of integrated photonic sensors. In addition, internal fs laser-induced modifications are characterized by a lower thermal stability as compared to the pristine polymer material. By performing a post-annealing process step, internal hollow microstructures are created by gaseous degradation of the exposed areas. Circular microchannels can be generated in a deliberately chosen layout by employing motorized 3D stages. In comparison to etching-based fabrication methods the proposed technology facilitates unlimited channel lengths, as it omits restrictions arising from an etching selectivity and duration. Altogether, this contribution paves the way towards the fabrication of internal three-dimensional optofluidic devices, equipped with a photonic sensor. In contrast, microfluidic and photonic structures are both created by femtosecond laser direct writing inside of transparent polymers.
This cover image outlines the fabrication method of a polymer planar Bragg grating electrified via femtosecond laser reductive sintering of CuO nanoparticles (see article number 2002203 by Stefan Kefer and co-workers). Based on this sophisticated methodology, bulk cyclic olefin copolymer substrates can be equipped with integrated photonic structures comprising a waveguide as well as a Bragg grating. Its reflective characteristics can be efficiently tuned by means of the subsequently generated Cu conducting path, whereas the applied femtosecond laser process enables an almost limitless degree of freedom towards conducting path geometries.