Fabrication of a vertically stacked grating coupler for optical waveguides in silicon-on-insulator

Couplers that can couple light vertically between stacked waveguides are finding importance in the push towards higher density and lower cost optoelectronics. A compact grating coupler (12.8mum) designed by a former student is implemented in this project. The device is patterned by reactive-ion-etch into silicon-on-insulator with a 250 nm thick device layer, ensuring single mode operation. Alignment marks are patterned into the backside so that aligned bonding can be carried out. A die bonding recipe is developed using an intermediate adhesive film of SU-8-2. A novel approach to creating optically smooth input facets is included in the final steps of the process. Optical testing remains to be done.