Waveguide system and methods

1. A waveguide apparatus, comprising:

a plurality of layers arranged to provide a plurality of waveguides, each of the plurality of waveguides extending in a direction parallel to one another in a direction of light travel and in a single plane, each of the plurality of layers forming a part of at least one respective waveguide;

wherein each of the plurality of layers comprises at least one alignment feature within the respective layer thereof and at least one first waveguide surface, the alignment feature being separate from the at least one first waveguide surface;

a first member and a second member;

wherein the first member is at least partially attached to the second member; and

wherein at least a portion of the plurality of layers is disposed between the first and second members; and

at least one alignment device disposed at least partially within the at least one alignment feature.

2. The apparatus of claim 1 , further comprising a second waveguide surface disposed on at least a portion of the plurality of layers; wherein at least a portion of the plurality of waveguides comprise the second waveguide surface.

3. The apparatus of claim 1 , further comprising a cover member comprising at least one waveguide surface.

4. The apparatus of claim 1 , wherein the first member and the second member are at least partially attached using an attachment method selected from the group of attachment methods consisting of: attachment using at least one latch, attachment using at least one clamp, attachment using at least one threaded fastener, attachment using an adhesive, attachment using a chemical weld, and attachment using a thermal weld.

5. A waveguide method, comprising:

stacking a plurality of layers to form a plurality of waveguides, each of the plurality of waveguides extending in a direction parallel to one another in a direction of light travel and in a single plane, each of the plurality of layers forming part of at least one respective waveguide;

wherein each of the plurality of layers comprises at least one alignment feature within the respective layer thereof and at least one first waveguide surface, the alignment feature being separate from the at least one first waveguide surface;

aligning the plurality of layers via at least one alignment device; and

trapping the aligned, stacked plurality of layers between a first member and second member.

6. The method of claim 5 , wherein at least a portion of the plurality of layers further comprise a second waveguide surface disposed on at least a portion of the plurality of layers;

at least a portion of the plurality of waveguides comprise the second waveguide surface.

7. The method of claim 5 , further comprising:

attaching at least a portion of the first member to the second member.

8. The method of claim 5 , further comprising:

attaching a cover member comprising at least one waveguide surface to at least a portion of the plurality of layers.

9. The method of claim 5 ,

wherein each of the plurality of layers comprises a thermplastic member; and

wherein the thermoplastic member is selected from the group of thermoplastic members consisting of: an injection molded member and an extruded member and a compression molded member.

10. The method of claim 5 , wherein each of the alignment devices comprises at least one surface feature attached to the first member.

11. The method of claim 10 ,

wherein each of the alignment devices comprises at least one projecting surface feature attached to the first member;

wherein each of the layers further comprises at least one alignment feature within the layer, the at least one alignment feature including an aperture adapted to accommodate the passage of at least a portion of at least one alignment device; and

wherein the second member further comprises at least one aperture adapted to accommodate the passage of at least a portion of at least one alignment device.

12. The method of claim 7 ,

wherein attaching at least a portion of the first member to the second member comprises non-detachably attaching at least a portion of the first member to at least a portion of the second member; and

wherein non-detachably attaching at least a portion of the first member to at least a portion of the second member comprises an attachment method selected from the group of attachment methods consisting of: an adhesive-based attachment method, a chemical weld-based attachment method, and a thermal weld based attachment method.

13. The method of claim 7 ,

wherein attaching at least a portion of the first member to the second member comprises detachably attaching at least a portion of the first member to at least a portion of the second member; and

wherein detachably attaching at least a portion of the first member to at least a portion of the second member comprises an attachment method selected from the group of attachment methods consisting of: at least one clamp, at least one latch, and at least one threaded fastener.

14. The method of claim 5 further comprising fabricating the first waveguide surface to a finish, characterized by a surface roughness in the range of 30 nm Ra or less.

15. The method of claim 5 , wherein the plurality of waveguides comprise a width of from about 100 μm to about 300 μm and a height of from about 100 μm to about 300 μm.

16. The method of claim 5 , wherein the plurality of waveguides comprise a center-to-center spacing of from about 150 μm to about 400 μm.

17. The apparatus of claim 1 , wherein each of the plurality of waveguides is a hollow-metal waveguide.

18. The apparatus of claim 1 , wherein the second member includes a complimentary aperture to accommodate the at least one alignment device.

19. The apparatus of claim 2 , wherein a first waveguide surface of a first layer of the plurality of layers and a second waveguide surface of a second layer of the plurality of layers combine to form a first waveguide of the plurality of waveguides, the first layer being adjacent to the second layer.

20. The apparatus of claim 1 , wherein the wave guide apparatus further comprises a single cover forming another part of each of the plurality of waveguides.

21. The method of claim 5 , wherein the plurality of layers are provided with a single cover, the single cover forming at least a part of each of the plurality of waveguides.