Owing to its many outstanding properties, polydimethylsiloxane (PDMS) has been an important engineering elastomer. An integration of compact, low-loss, three-dimensional (3D) optical waveguides with fluidic functionalities will greatly enhance the capabilities of PDMS-based devices and enable heretofore unimaginable applications. Recently, we have demonstrated the fabrication of compact polymer waveguides in PDMS through multiphoton laser direct writing both with and without a photoinitiator. While the photoinitiator-free process enjoyed a high refractive index contrast and a very low optical loss, it was subject to excessive defects due to material damage during the high-intensity optical irradiation. Our process using a photoinitiator achieved a defect-free fabrication despite a lower refractive index contrast and a higher loss. We show that the defects are a result of uncontrolled optical beam collapse through self-focusing and discuss potential solutions to mitigate the defects.
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