A novel Si/SiNx/Si trilayer diffusion source and mask is described and
applied to an alignment-free process for fabricating lasers by impuri
ty-induced disordering (IID). Edge emitting lasers with continuous wav
e threshold currents of 4.8 mA were achieved, and folded-cavity surfac
e-emitting lasers with Si disordered waveguides were demonstrated for
the first time with a threshold of 11 mA. The process that makes possi
ble self-aligned metallization on a diffusion defined stripe will be u
seful in fabricating narrow stripe IID lasers and simplify processing
for integration of no waveguide devices.