Processes for forming photonic bandgap structures

A method for making a photonic bandgap device including a matrix phase and a periodic structural array extending through said matrix phase, said method comprising the steps of:

• creating a representation of a mold for said photonic bandgap device on a computer, said representation including a plurality of segments defining said mold and a cavity within said mold;
• generating program signals corresponding to each of said segments in a predetermined sequence;
• providing a material having a fluid state and a solid state;
• forming a plurality of layers of said material on top of one another according to said program signals with the formation of each successive layer being controlled to take place after said material in said preceding layer has solidified, at least some of said layers including a mold portion containing said material in said solid state and a cavity portion not containing said material in said solid state, said mold portions corresponding to said matrix phase of said photonic bandgap device and said cavity portions corresponding to said periodic structural array of said photonic bandgap device;
• providing a suspension of a solid particulate material dispersed in a fluid vehicle;
• introducing said suspension into said mold to fill at least a portion of said cavity;
• and
• solidifying said suspension in said cavity, whereby said solidified suspension defines said periodic structural array of said photonic bandgap device and said mold occupies a region corresponding to said matrix phase of said photonic bandgap device.

A method for making a photonic bandgap device including a matrix phase and a periodic structural array extending through said matrix phase, said method comprising the steps of:

• creating a representation of a mold for said photonic bandgap device on a computer, said representation including a plurality of segments defining said mold and a cavity within said mold;
• generating program signals corresponding to each of said segments in a predetermined sequence;
• providing a material having a fluid state and a solid state;
• forming a plurality of layers of said material on top of one another according to said program signals with the formation of each successive layer being controlled to take place after said material in said preceding layer has solidified, at least some of said layers including a mold portion containing said material in said solid state and a cavity portion not containing said material in said solid state, said mold portions corresponding to said periodic structural array of said photonic bandgap device and said cavity portions corresponding to said matrix phase of said photonic bandgap device;
• providing a suspension of a solid particulate material dispersed in a fluid vehicle;
• introducing said suspension into said mold to fill at least a portion of said cavity;
• and
• solidifying said suspension in said cavity, whereby said solidified suspension defines said matrix phase of said photonic bandgap device and said mold occupies a region corresponding to said periodic structural array of said photonic bandgap device.