A method for fabricating optical devices comprises the steps of preparing
a first substrate wafer with at least one buried optical waveguide on an
approximately flat planar surface of the substrate and a second substrate
wafer with at least a second buried optical waveguide. The waveguides so
formed may be straight or be curved along the surface of the wafer or
curved by burying the waveguide at varying depth along its length. The
second wafer is turned (flipped) and bonded to the first wafer in such a
manner that the waveguides, for example, may form an optical coupler or
may crossover one another and be in proximate relationship along a region
of each. As a result, three dimensional optical devices are formed
avoiding conventional techniques of layering on a single substrate wafer.
Optical crossover angles may be reduced, for example, to thirty degrees
from ninety degrees saving substrate real estate. Recessed areas may be
provided in one or the other substrate surface reducing crosstalk in a
completed three dimensional crossover device. Three dimensional optical
couplers may comprise waveguides of identical or dissimilar
characteristics. Moreover, three dimensional optical switches may be
formed using the proposed flip and bond assembly process.