Improved performance of quantum cascade lasers through a scalable, manufacturable epitaxial-side-down mounting process.

We report substantially improved performance of high-power quantum cascade lasers (QCLs) by using epitaxial-side-down mounting that provides superior heat dissipation properties. We used aluminum nitride as the heatsink material and gold-tin eutectic solder. We have obtained continuous wave power output of 450 mW at 20 degrees C from mid-IR QCLs. The improved thermal management achieved with epitaxial-side-down mounting combined with a highly manufacturable and scalable assembly process should permit incorporation of mid-IR QCLs in reliable instrumentation.