Fabrication of Sub-Micron Polymer Waveguides through Two-Photon Polymerization in Polydimethylsiloxane

Free-standing millimeter-range 3D waveguides for on-chip optical interconnects

Next-generation energy-efficient photonic integrated systems, such as neuromorphic computational chips require efficient heterogeneous integration of ultracompact light sources and photodetectors through highly dense waveguide circuits. However, interconnecting these devices in emitter-receiver communication circuits remains a challenge and an obstacle towards upscaling heterogeneous photonic chips. Here we report on versatile air-cladded free-standing 3D polymer waveguides (OrmoCore, n≈1.5) spanning up to 900 µm in length without intermediate mechanical support structures, microprinted via two-photon polymerization. The presented waveguides are suitable for on-chip out-of-plane light coupling as well as non-connected 3D crossings, needed for high density optical circuits. The waveguides show optical transmission losses of 1.93 dB mm-1 at λ = 635 nm, and of 3.71 dB mm-1 at λ = 830 nm in the wavelength range of GaAs-based microLEDs spectral emission. On-chip imaging for high-precision alignment and TPP microfabrication are performed seamlessly by utilizing the same laser source for both steps, allowing accurate 3D printing on microstructured substrates. As proof of concept, we interconnect two GaAs-based microLEDs via an on-chip microprinted 3D waveguide. Such combined systems can serve as building blocks of future complex integrated heterogeneous photonic networks.

Towards clinical application of freehand optical ultrasound imaging

Freehand optical ultrasound (OpUS) imaging is an emerging ultrasound imaging paradigm that uses an array of fibre-optic, photoacoustic ultrasound sources and a single fibre-optic ultrasound detector to perform ultrasound imaging without the need for electrical components in the probe head. Previous freehand OpUS devices have demonstrated capability for real-time, video-rate imaging of clinically relevant targets, but have been hampered by poor ultrasound penetration, significant imaging artefacts and low frame rates, and their designs limited their clinical applicability. In this work we present a novel freehand OpUS imaging platform, including a fully mobile and compact acquisition console and an improved probe design. The novel freehand OpUS probe presented utilises optical waveguides to shape the generated ultrasound fields for improved ultrasound penetration depths, an extended fibre-optic bundle to improve system versatility and an overall ruggedised design with protective elements to improve probe handling and protect the internal optical components. This probe is demonstrated with phantoms and the first multi-participant in vivo imaging study conducted with freehand OpUS imaging probes, this represents several significant steps towards the clinical translation of freehand OpUS imaging.

Fabrication and Characterization of PDMS Waveguides for Flexible Optrodes

With the growth of optogenetic research, the demand for optical probes tailored to specific applications is ever rising. Specifically, for applications like the coiled cochlea of the inner ear, where planar, stiff, and nonconformable probes can hardly be used, transitioning from commonly used stiff glass fibers to flexible probes is required, especially for long-term use. Following this demand, polydimethylsiloxane (PDMS) with its lower Young's modulus compared to glass fibers can serve as material of choice. Hence, the long-term usability of PDMS as a waveguide material with respect to variations in transmission and refractive index over time is investigated. Different manufacturing methods for PDMS-based flexible waveguides are established and compared with the aim to minimize optical losses and thus maximize optical output power. Finally, the waveguides with lowest optical losses (-4.8 dB cm-1 ± 1.3 dB cm-1 at 472 nm) are successfully inserted into the optogenetically modified cochlea of a Mongolian gerbil (Meriones unguiculatus), where optical stimuli delivered by the waveguides evoked robust neuronal responses in the auditory pathway.

Complex Three-Dimensional Microscale Structures for Quantum Sensing Applications

We present a novel method for fabricating highly customizable three-dimensional structures hosting quantum sensors based on nitrogen vacancy (NV) centers using two-photon polymerization. This approach overcomes challenges associated with structuring traditional single-crystal quantum sensing platforms and enables the creation of complex, fully three-dimensional, sensor assemblies with submicroscale resolutions (down to 400 nm) and large fields of view (>1 mm). By embedding NV center-containing nanoparticles in exemplary structures, we demonstrate high sensitivity optical sensing of temperature and magnetic fields at the microscale. Our work showcases the potential for integrating quantum sensors with advanced manufacturing techniques, facilitating the incorporation of sensors into existing microfluidic and electronic platforms, and opening new avenues for widespread utilization of quantum sensors in various applications.

Pick and place process for uniform shrinking of 3D printed micro- and nano-architected materials

Two-photon polymerization lithography is promising for producing three-dimensional structures with user-defined micro- and nanoscale features. Additionally, shrinkage by thermolysis can readily shorten the lattice constant of three-dimensional photonic crystals and enhance their resolution and mechanical properties; however, this technique suffers from non-uniform shrinkage owing to substrate pinning during heating. Here, we develop a simple method using poly(vinyl alcohol)-assisted uniform shrinking of three-dimensional printed structures. Microscopic three-dimensional printed objects are picked and placed onto a receiving substrate, followed by heating to induce shrinkage. We show the successful uniform heat-shrinking of three-dimensional prints with various shapes and sizes, without sacrificial support structures, and observe that the surface properties of the receiving substrate are important factors for uniform shrinking. Moreover, we print a three-dimensional mascot model that is then uniformly shrunk, producing vivid colors from colorless woodpile photonic crystals. The proposed method has significant potential for application in mechanics, optics, and photonics.

Investigation on mode dispersion and lamination stability of multimode polymer waveguides for an optical backplane

In this paper, two noteworthy issues of mode dispersion and lamination stability of multimode polymer waveguides for optical backplane are investigated. In the case of center launching by 50-µm graded-index (GI) multimode fiber (MMF), mode dispersion of polymer waveguides with different widths is analyzed theoretically and measured in the view of bit error rate (BER) curves. Compared with the waveguide with the width of 40 µm, 1-dB power penalty is observed by the 70-µm-width waveguide due to its larger mode dispersion. On the other hand, waveguide stability after laminating process with high temperature and pressure is measured experimentally. No significant changes in core shape and size are observed. The average insertion loss of 80 channels before and after lamination are 0.137 dB/cm and 0.192 dB/cm, respectively. Error-free transmission at 25 Gb/s is obtained by laminated waveguides. The results imply the feasibility and potential of multimode waveguides for optical backplane.

Two-photon polymerization simulation and fabrication of 3D microprinted suspended waveguides for on-chip optical interconnects

Quantum and neuromorphic computational platforms in integrated photonic circuits require next-generation optical functionalities. Often, increasingly complex on-chip light-routing that allow superpositions not attainable by planar technologies are paramount e.g. for artificial neural networks. Versatile 3D waveguides are achievable via two-photon polymerization (TPP)-based microprinting. Here, a 3D morphology prediction tool which considers experimental TPP parameters, is presented, enabling on-chip 3D waveguide performance simulations. The simulations allow reducing the cost-intensive systematic experimental optimization process. Fabricated 3D waveguides show optical transmission properties in agreement with simulations, demonstrating that the developed morphology prediction methodology is beneficial for the development of versatile on-chip and potentially inter-chip photonic interconnect technology.

Photonic waveguide bundles using 3D laser writing and deep neural network image reconstruction

In recent years, three-dimensional (3D) printing with multi-photon laser writing has become an essential tool for the manufacturing of three-dimensional optical elements. Single-mode optical waveguides are one of the fundamental photonic components, and are the building block for compact multicore fiber bundles, where thousands of single-mode elements are closely packed, acting as individual pixels and delivering the local information to a sensor. In this work, we present the fabrication of polymer rectangular step-index (STIN) optical waveguide bundles in the IP-Dip photoresist, using a commercial 3D printer. Moreover, we reduce the core-to-core spacing of the imaging bundles by means of a deep neural network (DNN) which has been trained with a large synthetic dataset, demonstrating that the scrambling of information due to diffraction and cross-talk between fiber cores can be undone. The DNN-based approach can be adopted in applications such as on-chip platforms and microfluidic systems where accurate imaging from in-situ printed fiber bundles suffer cross-talk. In this respect, we provide a design and fabrication guideline for such scenarios by employing the DNN not only as a post-processing technique but also as a design optimization tool.

On the potential use of two-photon polymerization to 3D print chromatographic packed bed supports

The continuous quest for chromatographic supports offering kinetic performance properties superior to that of the packed bed of spheres has pushed the field to consider alternative formats such as for example monolithic and pillar array columns. This quest seems bound to culminate in the use of 3D printing technology, as this intrinsically offers the possibility to produce supports with a perfect uniformity and with a size and shape that is fully optimized for the chromatographic separation process. However, to be competitive with the current state-of-the-art, structures with sub-micron feature sizes are required. The present contribution therefore investigates the use of the 3D printing technology with the highest possible resolution available today, i.e., two-photon polymerization (2PP). It is shown that 2PP printing is capable of achieving the required ≤ 1 µm printing resolution. Depending on the laser scan speed, the lower limit through-pore size for a tetrahedral skeleton monolith with a theoretical 80% external porosity was found to be at 800 nm, when printing at a scan speed of 50 mm/s with a laser power of 10%. For a scan speed of 10 mm/s, the minimal through-pore size dropped to 500 nm. However, this very high resolution comes at the cost of excessively long printing times. The total printing time for a column volume equivalent to that of a typical nano-LC column (75 µm i.d. cylindrical tube with length L = 15 cm) has been determined to correspond to 330 and 470 h for the 50 mm/s and the 10 mm/s scan speed respectively. Other issues remaining to be solved are the need to clad the printed skeleton with a suitable mesoporous layer for chromatographic retention and the need to add a top-wall to the printed channels after the removal of the non-polymerized resin. It is therefore concluded that 2PP printing is not ready yet to replace the existing column fabrication methods.

The Rise of the OM-LoC: Opto-Microfluidic Enabled Lab-on-Chip

The integration of optical circuits with microfluidic lab-on-chip (LoC) devices has resulted in a new era of potential in terms of both sample manipulation and detection at the micro-scale. On-chip optical components increase both control and analytical capabilities while reducing reliance on expensive laboratory photonic equipment that has limited microfluidic development. Notably, in-situ LoC devices for bio-chemical applications such as diagnostics and environmental monitoring could provide great value as low-cost, portable and highly sensitive systems. Multiple challenges remain however due to the complexity involved with combining photonics with micro-fabricated systems. Here, we aim to highlight the progress that optical on-chip systems have made in recent years regarding the main LoC applications: (1) sample manipulation and (2) detection. At the same time, we aim to address the constraints that limit industrial scaling of this technology. Through evaluating various fabrication methods, material choices and novel approaches of optic and fluidic integration, we aim to illustrate how optic-enabled LoC approaches are providing new possibilities for both sample analysis and manipulation.

A Study on the Dynamic Forming Mechanism Development of the Negative Poisson's Ratio Elastomer Molds-Plate to Plate (P2P) Forming Process

This study proposed a dynamic forming mechanism development of the negative Poisson’s ratio elastomer molds—plate to plate (P2P) forming process. To dynamically stretch molds and control the microstructural shape, the proposal is committed to using the NPR structure as a regulatory mechanism. The NPR structural and dynamic parallel NPR-molds to control microstructure mold-cores were simulated and analyzed. ANSYS and MATLAB were used to simulate and predict dynamic NPR embossing replication. The hot-embossing and UV-curing dynamic NPR P2P-forming systems are designed and developed for verification. The results illustrated that the dynamic forming mechanism of the negative Poisson’s ratio elastomer molds proposed by this study can effectively control microstructure molds. This can effectively predict and calculate the geometrical characteristics of the microstructures after embossing. The multi-directional dynamic NPR microstructural replication process can accurately transfer microstructures and provide high transfer rate-replication characteristics.

Multiphoton Laser Fabrication of Hybrid Photo-Activable Biomaterials

The possibility to shape stimulus-responsive optical polymers, especially hydrogels, by means of laser 3D printing and ablation is fostering a new concept of “smart” micro-devices that can be used for imaging, thermal stimulation, energy transducing and sensing. The composition of these polymeric blends is an essential parameter to tune their properties as actuators and/or sensing platforms and to determine the elasto-mechanical characteristics of the printed hydrogel. In light of the increasing demand for micro-devices for nanomedicine and personalized medicine, interest is growing in the combination of composite and hybrid photo-responsive materials and digital micro-/nano-manufacturing. Existing works have exploited multiphoton laser photo-polymerization to obtain fine 3D microstructures in hydrogels in an additive manufacturing approach or exploited laser ablation of preformed hydrogels to carve 3D cavities. Less often, the two approaches have been combined and active nanomaterials have been embedded in the microstructures. The aim of this review is to give a short overview of the most recent and prominent results in the field of multiphoton laser direct writing of biocompatible hydrogels that embed active nanomaterials not interfering with the writing process and endowing the biocompatible microstructures with physically or chemically activable features such as photothermal activity, chemical swelling and chemical sensing.

Polymer Optical Waveguide Sensor Based on Fe-Amino-Triazole Complex Molecular Switches

We report on a polymer-waveguide-based temperature sensing system relying on switchable molecular complexes. The polymer waveguide cladding is fabricated using a maskless lithographic optical system and replicated onto polymer material (i.e., PMMA) using a hot embossing device. An iron-amino-triazole molecular complex material (i.e., [Fe(Htrz)_2.85(NH₂-trz)_0.15](ClO₄)₂) is used to sense changes in ambient temperature. For this purpose, the core of the waveguide is filled with a mixture of core material (NOA68), and the molecular complex using doctor blading and UV curing is applied for solidification. The absorption spectrum of the molecular complex in the UV/VIS light range features two prominent absorption bands in the low-spin state. As temperature approaches room temperature, a spin-crossover transition occurs, and the molecular complex changes its color (i.e. spectral properties) from violet-pink to white. The measurement of the optical power transmitted through the waveguide as a function of temperature exhibits a memory effect with a hysteresis width of approx. 12 °C and sensitivity of 0.08 mW/°C. This enables optical rather than electronic temperature detection in environments where electromagnetic interference might influence the measurements.