Nano patterning on optical fiber and laser diode facet with dry resist

Semiconductor micro and nanofabrication lithography techniques for application in microelectronics as well as in micromechanics and optoelectronics can gain significantly from using a dry resist process, since it enables the deposition of a very uniform lithographically sensitive layer on a potentially very small area. This would otherwise be extremely difficult to achieve by using a traditional spin coated resist, such as poly(methylmethacrylate) (PMMA). We demonstrate the use of an electron sensitive sterol based evaporated electron beam resist to fabricate high-resolution features (down to 100 nm) on a small surface area. This electron beam resist has a sensitivity comparable to PMMA and is deposited using a simple thermal evaporation. Two practical applications are explored: first, this resist makes it possible to fabricate a Fresnel zone plate lens on the tip of an optical fiber in order to demonstrate the principle and the potential of highly efficient coupling of diode laser emission into the fiber; second, we use this evaporated electron beam resist in order to pattern an optical diffractive element on the facet of a semiconductor laser. (C) 2004 American Vacuum Society.