We discuss the fabrication process and characteristics of three consec
utive runs of double-fused 1.5-mu m vertical-cavity lasers. We have me
asured light-current characteristics of over three hundred lasers with
ten different diameters between 6 and 60 mu m and observe a yield of
over 95%. The process and design improvements resulted in a low pulsed
threshold current of 3 mA on a number of 6- and 8-mu m-diameter devic
es and threshold current density of 2 kA cm(-2) on 60-mu m-diameter de
vices at room temperature.