There is growing interest in developing fabrication methods for optically nonlinear organic materials that are used in integrated optical modulators. Of particular interest are systems in which the NLO moiety is incorporated in a polymer system either as a dopant or chemically attached as a side chain to the polymer backbone. In order to realize the potential of these polymers, much research has been directed toward developing the technology required to form channel waveguides and demonstrate prototype polymeric modulators. Reported here are the fabrication details of a projection printing technique to form channel waveguides and prototype modulators. This technique has been used to characterize the optical properties of the polymers by the fabrication and testing of Mach Zehnder modulators. The projection printing technique forms inverted ribs in optical epoxies by noncontact exposure to a patterned UV light source. These inverted ribs are filled by spin coating with the electro-optic polymers to form channel waveguides. A second buffer layer is coated over the polymer by spinning and poling/device electrodes are added to form the completed modulator. Any spin coatable electro-optic polymer can be used as the active waveguide material by adjusting the inverted rib dimensions for single mode operation depending on the polymer/epoxy index difference. The practical engineering design considerations and fabrication procedures required for single mode channel waveguides and successful modulator construction are discussed in detail.