Patent ID: 7625515

Claim:
A method to manufacture a photonic crystal having a multi-layer structure, the multi-layer structure having a number of dielectric rods to form a plurality of planar layers, the plurality of planar layers one on the other to form a multi-dimensional structure, each planar layer having a plurality of dielectric rods arranged with parallel axes at a given spacing, each planar layer having its axes oriented at an approximately ninety degree angle with respect to adjacent planar layers, the method comprising: a) filling a plurality of grooves of an elastomeric mold with a first polymer that can be UV cured, each groove in the plurality of grooves in parallel with each other, so as to partially form the dielectric rods of one of the plurality of planar layers; b) partially curing the first polymer; c) coating a second polymer on the first polymer, resulting in a filled elastomeric mold to thereby complete formation of the dielectric rods of one of the plurality of planar layers; d) placing one of a substrate or a multi-layer polymer structure on the filled elastomeric mold; e) exposing the one of the substrate or the multi-layer polymer structure and the filled elastomeric mold to UV light; f) peeling the filled elastomeric mold away from the first polymer and the second polymer such that the first polymer and second polymer form a polymer layer of polymer rods on the one of the substrate and the multi-layer polymer structure; and g) forming the multi-layer polymer structure by repeating steps a to f until a desired number of polymer layers have been formed.