Birefringence in Injection-Molded Cyclic Olefin Copolymer Substrates and Its Impact on Integrated Photonic Structures.

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.

Integration of Bragg gratings in aerosol-jetted polymer optical waveguides for strain monitoring capabilities.

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.

Femtosecond Laser-Based Micromachining of Rotational-Symmetric Sapphire Workpieces.

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.

Space-variant polarization conversion with artificial birefringent metallic elements.

We present an artificial birefringent space-variant polarization converter for the near infrared, λ = 1550 nm. Each hollow waveguide has a rectangular shape with lateral dimensions of 1550 nm in the x-direction and 1034 nm as the largest length in the y-direction. The whole device consists of approximately 2000 × 2500 hollow waveguides realized in a 2-µm-thick gold structure. They are separated by sidewalls with a width of less than 500 nm. By proper choice of the lateral widths of the individual holes, a pixel-wise polarization conversion of an incoming wave field is possible. By suitable choice of the fabrication parameters, a birefringent phase shift up to 2π can be achieved. Hence, the structure is able to fully convert the state of polarization, e.g., from linear to circular. For fabrication of the device, femtosecond 3D direct laser writing was combined with electroplating. Here, we describe the operation of our device as a space-variant polarization converter by measuring the angle-dependent transmitted power and by calculating the ellipticity and the phase delay dependent on position as well as the azimuth angle from the experimentally determined powers.

Microstructure-Based Fiber-To-Chip Coupling of Polymer Planar Bragg Gratings for Harsh Environment Applications.

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.

Hypersensitive H2 sensor based on polymer planar Bragg gratings coated with Pt-loaded WO3-SiO2: erratum.

We present an erratum to our Letter [Opt. Lett.45, 3601 (2020)OPLEDP0146-959210.1364/OL.395341]. Labeling errors in two figures and an incorrect sentence are revised. The corrections have no influence on the conclusions of the original Letter.

Hypersensitive H2 sensor based on polymer planar Bragg gratings coated with Pt-loaded WO3-SiO2.

This Letter demonstrates a novel, to the best of our knowledge, 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 -37pm, 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.

Femtosecond laser inscription of waveguides and Bragg gratings in transparent cyclic olefin copolymers.

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.

Robust Polymer Planar Bragg Grating Sensors Embedded in Commercial-Grade Composites.

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.

Multipurpose Polymer Bragg Grating-Based Optomechanical Sensor Pad.

Flexible epoxy waveguide Bragg gratings are fabricated on a low-modulus TPX™ polymethylpentene polyolefin substrate for an easy to manufacture and low-cost optomechanical sensor pad providing exceedingly multipurpose application potentials. Rectangular EpoCore negative resist strip waveguides are formed employing standard UV mask lithography. Highly persistent Bragg gratings are inscribed directly into the channel waveguides by permanently modifying the local refractive indices through a well-defined KrF excimer laser irradiated +1/-1 order phase mask. The reproducible and vastly versatile sensing capabilities of this easy-to-apply optomechanical sensor pad are demonstrated in the form of an optical pickup for acoustic instruments, a broadband optical accelerometer, and a biomedical vital sign sensor monitoring both respiration and pulse at the same time.

High-temperature stable and sterilizable waveguide Bragg grating in planar cyclo-olefin copolymer.

In this Letter, we demonstrate a high-temperature stable polymer planar waveguide Bragg grating based on cyclo-olefin copolymers. The high glass transition temperature of the polymer material amounting to 178°C, in conjunction with a high-temperature stable UV-curable adhesive used to connect the polymer sensor to a standard single-mode fiber, enables temperature readings of up to 160°C while exhibiting a temperature sensitivity of -7.3 pm/°C. The reflected power of the Bragg wavelength remains constant up to a temperature of 130°C before declining at higher temperatures with an overall reduction of 2.5 dB at 160°C. However, decreasing temperature results in a complete recovery of the peak power, facilitating steam pressure sterilization (129°C, 0.17 MPa) of the polymer planar waveguide Bragg grating.