Laser micro-fabrication of concave, low-roughness features in silica

We describe a micro-fabrication method to create concave features with ultra-low surface roughness in silica, either on the end facets of optical fibers or on flat substrates. The machining uses a single focused CO2 laser pulse. Parameters are chosen such that material is removed by thermal evaporation while simultaneously producing excellent surface quality by surface tension-induced movement in a low-viscosity melt layer. A surface roughness σ~0.2nm is regularly obtained. The concave depressions are near-spherical close to the center with radii of curvature between 20 and 2000μm. The method allows the fabrication of low-scatter micro-optical devices such as mirror substrates for high-finesse cavities or negative lenses on the tip of optical fibers, extending the range of micro-optical components.