Polymer optical waveguides are efficiently produced using flexographic printing, enabling fast and cost-effective manufacturing. However, the small print height results in a cross-sectional area too small for effective light coupling. To address this, multiple layers are printed to achieve the required waveguide dimensions. This sequential printing process prolongs processing time as material is repeatedly fed into the machine, potentially leading to issues like dust inclusions and oxygen inhibition. This study demonstrates modifying flexographic printing forms to increase transferred material height by up to 20 % in a single pass. Different microstructure geometries (hexagon, triangle, and square) with varying depths were inserted into the printing form to analyze their effects on material transfer. The use of a UV-nanosecond laser and a mask-based process allowed for precise insertion of the microstructures, resulting in high geometric accuracy and homogeneous ablation.
Read full abstract