Fabrication of the plastic component for photonic crystal using micro injection molding

In this decade, many techniques have been introduced to fabricate photonic crystal in optical applications. Most of the processes used to fabricate the photonic crystal are time consuming and not cost effective. This study demonstrates an efficient method to fabricate photonic crystals. A polymer-based photonic crystal slab has been developed by embedding mixture with a high dielectric constant. Photonic crystals have patterned structures in which periodicity of dielectric properties can manipulate electromagnetic waves. The operation wavelength is about half of the characteristic dimension. Technique of injection molding is applied to make polymer parts with the photonic crystal pattern. Then mixture of barium titanate powder and epoxy is embedded on the patterned structure of the polymer part. The contrast of dielectric coefficients between mixture and polymer can constitute a structure with some photonic band gap. By means of polymer processing, mass production of photonic crystal devices like optical switch, optical waveguide, optical filter and so forth can be realized in a cost effective way.