In the context of the quest for the Organic Laser Diode, we present the multiscale fabrication process optimization of mixed-order distributed-feedback micro-cavities integrated in nanosecond-short electrical pulse-ready organic light-emitting diodes (OLEDs). We combine ultra-short pulsed electrical excitation and laser micro-cavities. This requires the integration of a highly resolved DFB micro-cavity with an OLED stack and with microwave electrodes. In a second challenge, we tune the cavity resonance precisely to the electroluminescence peak of the organic laser gain medium. This requires precise micro-cavity fabrication performed using e-beam lithography to pattern gratings with a precision in the nanometer scale. Optimal DFB micro-cavities are obtained with 300 nm thick hydrogen silsesquioxane negative-tone e-beam resist on 50 nm thin indium tin oxide anode exposed with a charge quantity per area (i.e., dose) of 620 µC/cm2, developed over 40 min in tetramethylammonium hydroxide diluted in water. We show that the integration of the DFB micro-cavity does not hinder the pulsed electrical operability of the device, which exhibits a peak current density as high as 14 kA/cm2.
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