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Hybrid photonic integration exploits complementary strengths of differentmaterial platforms, thereby offering superior performance and designflexibility in comparison to monolithic approaches. This applies in particularto multi-chip concepts, where components can be individually optimized andtested on separate dies before integration into more complex systems. Theassembly of such systems, however, still represents a major challenge,requiring complex and expensive processes for high-precision alignment as wellas careful adaptation of optical mode profiles. Here we show that thesechallenges can be overcome by in-situ nano-printing of freeform beam-shapingelements to facets of optical components. The approach is applicable to a widevariety of devices and assembly concepts and allows adaptation of vastlydissimilar mode profiles while considerably relaxing alignment tolerances tothe extent that scalable, cost-effective passive assembly techniques can beused. We experimentally prove the viability of the concept by fabricating andtesting a selection of beam-shaping elements at chip and fiber facets,achieving coupling efficiencies of up to 88 % between an InP laser and anoptical fiber. We also demonstrate printed freeform mirrors for simultaneouslyadapting beam shape and propagation direction, and we explore multi-lenssystems for beam expansion. The concept paves the way to automated fabricationof photonic multi-chip assemblies with unprecedented performance andversatility.

In-Situ 3D Nano-Printing of Freeform Coupling Elements for Hybrid Photonic Integration