Molded Light Pipe Optical Turn

An optical pipe comprising:

• a base element, comprising:
• a first base surface comprising N metal-coated grooves;
• a second base surface, orthogonal to the first base surface, comprising N metal-coated grooves;
• and
• a third base surface meeting the first and second base surfaces at 45 degrees, comprising a first mirror;
• a midsection block comprising:
• a first midsection surface comprising N metal-coated grooves;
• a second midsection surface, meeting the first midsection surface at 90 degrees, comprising N metal coated grooves;
• a third midsection surface comprising N metal-coated grooves;
• a fourth midsection surface, orthogonal to the third midsection surface, comprising N metal coated grooves;
• and
• a fifth midsection surface meeting the third and fourth midsection surfaces at 45 degrees, comprising a second mirror;
• and
• a top block comprising:
• a first top surface comprising N metal-coated grooves;
• and
• a second top surface, meeting the first base surface at 90 degrees, comprising N metal coated grooves;
• wherein the first and second midsection surfaces contact the first and second base surfaces such that a first set of N hollow waveguides are formed therebetween;
• wherein the third and fourth midsection surfaces contact the first and second top surfaces such that a second set of N hollow waveguides are formed therebetween;
• and
• wherein the first and second mirrors reflect guided optical beams through 90 degrees during passage of the guided optical beams through the first and second set of N hollow waveguides respectively.

A method of fabricating an optical pipe;

• the method comprising:
• molding a base component such that the base component comprises:
• a first base surface comprising N parallel grooves;
• a second base surface, orthogonal to the first base surface, comprising N parallel grooves;
• and
• a third base surface, meeting the first and second base surfaces at 45 degrees;
• molding a midsection component such that the midsection comprises:
• a first midsection surface comprising N parallel grooves;
• a second midsection surface, meeting the first midsection surface at 90 degrees, comprising N parallel grooves;
• a third midsection surface comprising N parallel grooves;
• a fourth midsection surface, orthogonal to the third midsection surface, comprising N parallel grooves;
• and
• a fifth midsection surface meeting the third and fourth midsection surfaces at 45 degrees;
• molding a top component such that the top component comprises:
• a first top surface comprising N parallel grooves;
• and
• a second top surface, meeting the first base surface at 90 degrees, comprising N parallel grooves;
• and
• depositing a reflective coating over:
• the grooves in each of the base, midsection, and top components;
• the third base surface;
• and
• the fifth midsection surface.