This Small Business Innovation Research (SBIR) Phase I project will apply silicon optical bench technology to manufacture lasers which are low-cost and ultra-compact. Diode-pumped solid-state (DPSS) lasers have yet to achieve mass-market penetration because of costs associated with current manufacturing techniques and laser designs. This Phase I addresses the fundamental laser design necessary to allow batch processing and miniaturization. The research will: demonstrate a miniaturized single frequency diode laser in a novel configuration; demonstrate frequency-doubling of this laser into the blue using passive optical locking;and demonstrate use of silicon optical bench technology for mounting components used in these lasers. The work will involve implementing frequency control of a laser diode using a miniaturized Fox-Smith interferometer. Cavity components will be designed, fabricated, assembled; and the laser performance will be characterized. This laser will be frequency-doubled into the blue using a small potassium niobate insert in the cavity. In parallel, design and processing of silicon wafers for mounting will be investigated using photolithography and anisotropic etching. Low-cost blue lasers will find important applications in the consumer optical data storage market. WDM communications and cable TV represent large markets for 1.3 micron lasers. Green versions will replace inefficient helium-neon lasers in laser pointers and other applications. Lower volume markets exist in printed circuit board inspection, instrumentation, and materials processing.
