A Vertical Cavity Surface Emitting Laser (VCSEL) assembly including a
VCSEL structure having a light-emitting region located on its surface, a
relatively wettable region of a surface modifier coating formed over the
light emitting region, and a microlens formed on the relatively wettable
region. A relatively non-wettable region of the surface modifier coating
is formed around the light-emitting region (e.g., on the electrode
surrounding the light-emitting region). The surface modifier coating is
formed, for example, from one or more organothiols that change the
surface energies of the light-emitting region and/or the electrode to
facilitate self-assembly and self-registration of the microlens material.
The microlens material is printed, microjetted, or dip coated onto the
VCSEL structure such that the microlens material wets to the relatively
wettable region, thereby forming a liquid bead that is reliably
positioned over the light-emitting region. The liquid bead is then cured
to form the microlens.