The invention relates to a process a process for forming single-mode, organic waveguides employing organic polymeric materials. The process reduces dissolved and
gaseous oxygen content to very low quantities, resulting in production of waveguides having superior properties and manufacturability. Also provided is a process for preventing loss of light due to cores having flared ends. A
waveguide is produced by sequentially a layer of a liquid, photosensitive buffer and clad composition to a surface of a substrate; deoxygenating under vacuum; overall exposing under an
inert gas actinic
radiation to partially polymerize the compositions below a full curing.
Coating a photosensitive core composition to the clad composition; deoxygenating under vacuum, covering with an
inert gas
atmosphere; positioning a
photomask above, but not in contact with the core layer; imagewise exposing the core through a
photomask pattern to actinic
radiation to partially polymerize the core composition; developing core;
coating a photosensitive overclad composition over the image areas of the core composition; deoxygenating under vacuum; overall exposing the overclad composition, under
inert gas to actinic
radiation to substantially fully cure the optional buffer composition, the underclad composition, the core composition and the clad composition.