Method of fabricating an optical waveguide

摘要

A method of fabricating an optical waveguide (10) includes using an electrical discharge machine (20) to fabricate mold plates (41, 61) for molding cladding layers (11, 12) of the optical waveguide (10). The cladding layers (11, 12) contain rounded edges (15, 16) which are aligned to form a cylindrical channel or core (13). The cylindrical shape of the channel (13) improves the reliability of the waveguide (10) compared to waveguides having a conventional square or rectangular channel with sharp corners. An optically transparent material (17) fills the cylindrical channel (13) and serves as the medium through which light is transmitted. The refractive index of the optically transparent material (17) is greater than that of the cladding layers (11, 12) to keep the light within the cylindrical channel. The optically transparent material (17) also serves as an adhesive for the cladding layers (11, 12).