Novel architecture and fabrication processes for single epitaxial growth distributed-feedback lasers for sensing and communication.

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Specialised Compound semiconductor (CS) lasers with Distributed Feedback (DFB) are used for high-speed datacom networks and in LiDAR (Light Detection And Ranging) for navigation and obstacle avoidance by autonomous vehicles and robots. Applications require DFB lasers which feature high optical powers and narrow linewidths, that operate in a range of environments.Current DFB lasers are manufactured in multiple steps by specialised suppliers at different sites: CS base layer is grown onto wafer-scale substrates, then sent to another supplier for a custom grating pattern to be defined using electron beam lithography, before being sent back to the CS material supplier to complete the structure. This extended supply chain increases manufacturing lead-times from weeks to months, and additional material handling increases chip-scale defects, lowering yield and increasing costs.For the market to accommodate the number of devices required, the technology needs to be commoditised to drive a cost reduction of ~10x. Innovation is needed to replace the current multi-step approach. This project will focus on developing novel device architectures, associated material-scale product which will increase yield, lower production lead-times and costs of manufacture. The methods used will be verified by testing laser performance and reliability.