Continuous melt processing of all-polymer distributed feedback lasers

Novel processing techniques for low-cost production of photonic devices could open up new applications for functional polymer systems. To this end, we have used multilayer coextrusion in a continuous melt process to fabricate large-area polymeric nanolayer films for optically-pumped all-polymer distributed feedback (DFB) surface-emitting lasers. Each laser film consists of hundreds of alternating layers of two transparent polymers with different refractive indices, of which one contains a laser dye. The resulting DFB lasers emit at defect states and show efficiencies as high as 8% and threshold fluences as low as 100 µJ/cm2.