The invention relates to a process a process for forming single-mode, organic
waveguides employing organic polymeric materials. The process reduces dissolved
and gaseous oxygen content to very low quantities, resulting in production of waveguides
having superior properties and manufacturability. Also provided is a process for
preventing loss of light due to cores having flared ends. A waveguide is produced
by sequentially a layer of a liquid, photosensitive buffer and clad composition
to a surface of a substrate; deoxygenating under vacuum; overall exposing under
an inert gas actinic radiation to partially polymerize the compositions below a
full curing. Coating a photosensitive core composition to the clad composition;
deoxygenating under vacuum, covering with an inert gas atmosphere; positioning
a photomask above, but not in contact with the core layer; imagewise exposing the
core through a photomask pattern to actinic radiation to partially polymerize the
core composition; developing core; coating a photosensitive overclad composition
over the image areas of the core composition; deoxygenating under vacuum; overall
exposing the overclad composition, under inert gas to actinic radiation to substantially
fully cure the optional buffer composition, the underclad composition, the core
composition and the clad composition.