Photonic Crystal - Fabrication Challenges

Fabrication Challenges

The major challenge for higher dimensional photonic crystals is in fabrication of these structures, with sufficient precision to prevent scattering losses blurring the crystal properties and with processes that can be robustly mass produced. One promising method of fabrication for two-dimensionally periodic photonic crystals is a photonic-crystal fiber, such as a "holey fiber". Using fiber draw techniques developed for communications fiber it meets these two requirements, and photonic crystal fibres are commercially available. Another promising method for developing two-dimensional photonic crystals is the so-called photonic crystal slab. These structures consist of a slab of material (such as silicon) which can be patterned using techniques borrowed from the semiconductor industry. Such chips offer the potential to combine photonic processing with electronic processing on a single chip.

For three dimensional photonic crystals, various techniques have been used including photolithography and etching techniques similar to those used for integrated circuits. Some of these techniques are already commercially available. To circumvent nanotechnological methods with their complex machinery, alternate approaches have been followed to grow photonic crystals as self-assembled structures from colloidal crystals.

Mass-scale 3D photonic crystal films and fibres can now be produced using a shear-assembly technique which stacks 200-300 nm colloidal polymer spheres into perfect films of fcc lattice. Because the particles have a softer transparent rubber coating the films can be stretched and molded, tuning the photonic bandgaps and producing striking structural color effects.