Integrated optical component and method of making

A method of making an optical component, comprising:

• laminating a reflective polarizer between a first polymeric plate and a second polymeric plate, the first polymeric plate having a first outer surface and the second polymeric plate having an opposing second outer surface;
• milling a plurality of parallel first troughs in the second polymeric plate at a 45 degree angle to the reflective polarizer to a first bottom, each parallel first trough separating a stair step riser from a first prism surface of a polarizing beam splitter (PBS) cube;
• milling a plurality of parallel second troughs perpendicular to the first troughs thereby forming a plurality of stair step treads, each of the stair step treads coplanar with the first bottom and extending from a first riser to an adjacent second riser, wherein each second trough separates end faces of adjacent PBS cubes on the tread, and an intersection of the tread and the riser defines a first hinge proximate the first outer surface;
• optionally milling a plurality of parallel third troughs each having a third bottom, each parallel to the first troughs, each of the parallel third troughs being perpendicular to the corresponding stair step riser and forming a flange supporting the PBS cubes, the third bottom separated from the tread by a second hinge;
• and
• milling a plurality of notches parallel to the first troughs, each notch having a first notch surface parallel to the tread and a second notch surface parallel to and extending into the riser, wherein the first notch surface comprises a fourth prism surface opposite the tread and the second notch surface comprises a third prism surface opposite the first prism surface,
• wherein the milling steps can be performed in any order.