News: Optoelectronics
27 October 2021
BluGlass’ optical facet and metallization laser diode design iterations now in post-epi production
BluGlass Ltd of Silverwater, Australia – which has developed proprietary low-temperature, low-hydrogen remote-plasma chemical vapor deposition (RPCVD) technology for manufacturing devices such as laser diodes, next-generation LEDs and micro-LEDs – has provided an update for fiscal first-quarter 2022 (to end-September 2021), including progress in its development of laser diodes.
Laser diode progress
BluGlass says that it continues to develop and test multiple iterations of its commercial laser diode prototypes, including single-mode and multi-mode products in 405nm, 420nm and 450nm wavelengths.
Alongside addressing flaws in the optical facet, BluGlass has also been improving metallization of the laser diode prototypes. Metallization is critical to laser diode development as it controls the input of electrical current into the laser as well as the removal of heat from the device. BluGlass is using analytical techniques to focus on failure modes to determine which components and processes within the manufacturing supply chain are causing issues.
Both the optical facet and metallization are in the post-epitaxy production steps, which are currently outsourced to third-party manufacturing suppliers.
BluGlass says that it is focused on improving the reliability of its laser diodes and has several iterations progressing through the manufacturing supply chain. Since June, the firm has conducted extensive failure analysis and burn-in testing of multiple development iterations. BluGlass has progressed four legacy iterations to completion that were in the manufacturing pipeline before June. These development efforts have resulted in improved manufacturing processes being implemented at all steps of the supply chain, with a strong focus on improvements to the firm’s front-end and back-end fabrication steps, and facet coating designs.
Following this extensive analysis and new process implementations, BluGlass has implemented two new design iterations. Testing of its first iterations of new laser diodes, which feature new metallization and optical facet improvements, will commence in the coming weeks.
BluGlass is focusing on eliminating variation between manufacturing suppliers, ensuring process and product repeatability – key steps for supply chain readiness ahead of commercial manufacturing.
“Laser diodes are complex technology and, while frustrating, reliability challenges are common within the industry,” notes president Jim Haden. “I have personally experienced and solved many of these development pitfalls for other companies over the past few decades. There are four elements that are key to producing optimal laser diodes: high-gain, low-loss epitaxy; low-resistance metallization; low-loss, passivating facets; and mechanically sound thermal management for packaging,” he adds. “Early prototype testing reassures us that our epitaxy is performing in line with expectations. Alongside our third-party fabrication specialists, the team is focused on optimizing the other three key elements and ultimately solving the primary cause of our reliability challenges.”
Haden will provide an update on laser diode development at the firm’s Annual General Meeting in November.
World-first tunnel-junction laser diodes
In August, BluGlass demonstrated working tunnel-junction laser diodes in a world-first proof-of-concept using its RPCVD technology.
The RPCVD tunnel-junction prototypes have demonstrated good lasing behaviour, confirming the potential of these enhanced designs to address the 50% performance loss presently suffered by gallium nitride (GaN) laser diodes due to excess heat. BluGlass says that its laser diode designs replace the magnesium-containing layers that cause optical and performance loss with an RPCVD tunnel-junction and second n-type cladding layer (a dual nwave laser diode).
“Our RPCVD tunnel-junction laser diodes are designed to significantly improve GaN laser diode performance. This will enable higher-power, brighter and more efficient lasers for commercial applications, including advanced 3D printing applications for automotive, defence and aerospace manufacturing as well as industrial welding for electronics, battery and automotive manufacturing,” says executive chair James Walker. “This successful proof-of-concept is an important technical and commercial validation. It demonstrates the capability of our RPCVD epitaxy to create brighter and better performing blue GaN laser diodes to support future applications and new wavelengths, providing a significant long-term growth opportunity for the business.”
Leadership changes
In September, BluGlass appointed US-based expert laser diode executive Jim Haden as president to lead the firm to profitability. Haden has more than 30 years of laser industry expertise gained in senior leadership roles at several of BluGlass’ prospective customers and competitors, including Kyocera SLD, nLight and Coherent. He has proven experience solving technical challenges, delivering products to market, and driving transformational revenue growth for advanced technology businesses, says BluGlass.
To aid the transition, executive chair James Walker remains in the role, supporting BluGlass’ financial and governance functions as the firm nears commercialization and profitability.
“Jim’s wealth of GaN laser expertise and commercialization experience will be instrumental in our transition to a global provider of next-generation laser diode products,” believes Walker. “While laser diode reliability issues are new to BluGlass, Jim has encountered and solved similar technical and operational challenges many times before. He has a deep understanding of this domain, with hands-on experience improving laser diode performance and building market share in underserved segments,” he adds.
“Jim’s appointment further enhances our board and senior management bench strength, complementing the industry expertise of Jean-Michel [Peleprat] and preparing BluGlass for its next growth phase. The calibre of the talent we are now attracting reflects our truly disruptive technology and significant market opportunity,” Walker reckons.
Outlook
BluGlass says that it remains focused on solving its reliability issues ahead of launching its direct-to-market laser diode products and securing the first customer orders.
“We have had a productive start to fiscal year 2022 and are now well-equipped to deliver on our growth strategy,” reckons Walker. “Under Jim’s leadership, we are well positioned to resolve our reliability challenges and optimize the performance of our first direct-to-market laser diodes. Our initial products will include the in-demand and under-served 405nm, 420nm and 450nm wavelengths, where we have collaborative customers with confirmed interest. While the majority of our focus is on the initial product range, we are also progressing the development of our novel RPCVD enhanced tunnel-junction laser diodes, which will offer more efficient and brighter, higher-performing blue GaN laser diodes and open the door to new applications and markets,” he adds.
“We are preparing our supply chain for scale while also increasing our in-house production capability and expertise. This end-to-end capability enables us to meet unmet industry demand for small custom batches as well as volume production,” concludes Walker.
BluGlass appoints US-based ex-Soraa/nLIGHT/Coherent/JDSU veteran as president
BluGlass demos first RPCVD tunnel-junction laser diodes
BluGlass now funded through to first commercial orders
BluGlass’ prototype lasers meet commercial power and wavelength specs
Nuburu co-founder Pelaprat joins BluGlass’ board
