Abstract
Silicon micromachining is applied to the fabrication of highly precise mould inserts to be used in the micro-replication of polymer waveguide components with integrated fibre alignment grooves. The waveguide structures with rectangular cross-section are realised by an anisotropic RIE process, whereas the integrated passive fibre alignment grooves are formed by anisotropic wet chemical etching. Two processes (a two-mask process and a selfaligned one-mask process) are described for the accurate alignment of waveguide structures and fibre alignment grooves.

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