Rapid prototyping of polymer waveguides by contour shaping

The current development in micro optical components demands for fast and reliable manufacturing processes. A prominent way of manufacturing in this area is mechanical machining. Due to long process times and for economic reasons the machined part acts afterwards as master in replication processes for higher lot sizes. We present a novel method of mechanical micro structuring which combines benefits of conventional ultra-precision milling and fly-cutting with a dramatic decrease in process time. The so-called contour shaping is based on non-rotational tool cutting. The machine is built of three high-speed linear axis in combination with a rotatable tool mount for turning the geometrically defined tool in working direction. Contour shaping enables mechanical micro structuring for rapid prototyping of optical components and in higher lot sizes the possibility of making a replication step obsolete. For a first demonstration, polymeric waveguides are manufactured by means of hot embossing for filling and capping of the shaped grooves. The surface parameters of the grooves as well as a demonstration of optical function of the waveguides is shown.