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Fabrication of large area (sub 1 cm cross-section) micro-optical componentsin a short period of time (approximately 10 min) and with lesser number ofprocessing steps is highly desirable and cost-effective. In the recent years,femtosecond laser fabrication technology has revolutionized the field ofmanufacturing by offering the above capabilities. In this study, a fundamentaldiffractive optical element, binary axicon i.e axicon with two phase oramplitude levels, has been designed in three configurations namely conventionalaxicon, photon sieve axicon (PSA) and sparse PSA and directly milled onto theSapphire substrate. The fabrication results revealed that a single pulse burstfabrication can produce a flat and smooth profile than pulse overlappedfabrication which gives rise to surface damage and increased roughness. Thefabricated elements were processed in IsoPropyl Alcohol and Potassium Hydroxideto remove debris and redeposited amorphous Sapphire. An incoherent illuminationwas used for optical testing of the components and a non-linear optical filterwas used for cleaning the noisy images generated by the diffractive opticalelements.

Imaging with Diffractive Axicons Rapidly Milled on Sapphire by Femtosecond Laser Ablation