Silicon photonics researchers across the UK can now send their chip designs to a central fabrication hub at Southampton and Glasgow universities, which will build them for free or at a steep discount. The problem is that designing and testing a silicon photonics device—which uses light rather than electrons to process information—is relatively cheap and easy, but actually manufacturing one requires multi-million-pound cleanrooms, lithography scanners, and etching tools that most university labs cannot afford. CORNERSTONE 2.5 fills that gap by offering a shared, wafer-scale fabrication service. It bundles multiple users’ designs onto a single 8-inch silicon wafer, dramatically cutting per-project costs. If the service succeeds, it could accelerate development of faster, lower-energy data communications, quantum photonics circuits, and highly sensitive chemical or biological sensors. The same fabrication line also supports micro-electromechanical systems (MEMS) and microfluidics, so the impact could ripple across medical diagnostics, environmental monitoring, and optical computing. A network of commercial partners—from software specialists to packaging foundries—means researchers can take a design from concept to a packaged prototype without leaving the academic ecosystem. The project will also test whether demand is strong enough to make CORNERSTONE a permanent national facility.
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Silicon photonics is the manipulation of light (photons) in silicon-based substrates, analogous to electronics, which is the manipulation of electrons. The development cycle of a silicon photonics device consists of three stages: design, fabrication, and characterisation. Whilst design and characterisation can readily be done by research groups around the country, the fabrication of silicon photonics devices, circuits and systems requires large scale investments and capital equipment such as cleanrooms, lithography, etching equipment etc. Based at the Universities of Southampton and Glasgow, CORNERSTONE 2.5 will provide world-leading fabrication capability to silicon photonics researchers and the wider science community. Whilst silicon photonics is the focus of CORNERSTONE 2.5, it will also support other technologies that utilise similar fabrication processes, such as MEMS or microfluidics, and the integration of light sources with silicon photonics integrated circuits, as well as supporting any research area that requires high-resolution lithography. The new specialised capabilities available to researchers to support emerging applications in silicon photonics are: 1) quantum photonics based on silicon-on-insulator (SOI) wafers; 2) programmable photonics; 3) all-silicon photodetection; 4) high efficiency grating couplers for low energy, power sensitive systems; 5) enhanced sensing platforms; and 6) light source integration to the silicon nitride platform. Access will be facilitated via a multi-project-wafer (MPW) mechanism whereby multiple users' designs will be fabricated in parallel on the same wafer. This is enabled by the 8" wafer-scale processing capability centred around a deep-UV projection lithography scanner installed at the University of Southampton. The value of CORNERSTONE 2.5 to researchers who wish to use it is enhanced by a network of supporting companies, each providing significant expertise and added value to users. Supporting companies include process-design-kit (PDK) software specialists (Luceda Photonics), reticle suppliers (Compugraphics, Photronics), packaging facilities (Tyndall National Institute, Bay Photonics, Alter Technologies), a mass production silicon photonics foundry (CompoundTek), an epitaxy partner for germanium-on-silicon growth (IQE), fabrication processing support (Oxford Instruments), an MPW broker (EUROPRACTICE), a III-V die supplier (Sivers Semiconductors) and promotion and outreach partners (Photonics Leadership Group, EPIC, CSA Catapult, CPI, Anchored In). Access to the new capabilities will be free-of-charge to UK academics in months 13-18 of the project, and 75% subsidised by the grant in months 19-24. During the 2-year project, we will also canvas UK demand for the capability to continue to operate as an EPSRC National Research Facility, and if so, to establish a Statement of Need.
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