Slanted gratings show high efficiency in coupling light into waveguides, which is critical for optics such as the diffractive optical elements (DOEs) used in augmented reality glasses. Fabrication of master molds used for producing slanted gratings require high etch selectivity between SiO2 and a metal mask. The industry standard for trench etch, Reactive Ion Etch (RIE), cannot produce slanted trenches. In this work, we demonstrate the fabrication of surface relief grating (SRG) master molds with slant angles of 30, 45 and 60 degrees. Using Reactive Ion Beam Etch (RIBE), etch anisotropy is controlled via the directionality of the ion beam, combined with angle of incidence. The selectivity between metal mask vs SiO2 can be tuned (7:1 to 12:1). An in-house oxygen cleaning increases stability, leading to high repeatability in process and etch rates. High static uniformity across the wafer surface was achieved using a proprietary tunable ion source.
The field of ultraviolet (UV)-laser applications is currently experiencing rapid growth in the semiconductor processing, laser micromachining and biomedical markets. A key enabler for these technologies are optical coatings used to manipulate and direct laser beams in a targeted manner. As laser power, laser fluence and pulse frequencies increase, the demands on the physical properties of the coating materials become more stringent. We demonstrate how ion beam sputtering and post-deposition heat treatment are utilized to produce low loss optical coatings at 355 nm and 266 nm. The importance of precisely controlling the sputtering conditions for individual materials is highlighted and the influence of different process parameters on the resulting material properties is discussed. The effect of annealing on key performance parameters for optical coatings such as absorption, stress, roughness, and film structure is investigated. The low absorption achieved in this work results in high laser induced damage thresholds (LIDT) exceeding 2.5 J/cm2 and 6.5 J/cm2 for highly reflective (HR) mirrors and 7.6 J/cm2 and 15.7 J/cm2 for antireflective coatings at 266 nm and 355 nm, respectively.
Slanted gratings show high efficiency in coupling light into waveguides, which is critical for optics such as the diffractive optical elements (DOEs) used in augmented reality glasses. Fabrication of master molds used for producing slanted gratings require high etch selectivity between SiO2 and a metal mask. The industry standard for trench etch, Reactive Ion Etch (RIE), cannot produce slanted trenches. In this work, we demonstrate the fabrication of surface relief grating (SRG) master molds with slant angles of 30, 45 and 60 degrees. Using Reactive Ion Beam Etch (RIBE), etch anisotropy is controlled via the directionality of the ion beam, combined with angle of incidence. The selectivity between metal mask vs SiO2 can be tuned (7:1 to 12:1). An in-house oxygen cleaning increases stability, leading to high repeatability in process and etch rates. High static uniformity across the wafer surface was achieved using a proprietary tunable ion source.
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