Background: The benefits of microresonator lasers include easy and low-cost fabrication methods and high-quality factor of microresonators, which results in low threshold current of the fabricated laser. However, the lack of tunable fabrication methods with precise size and spacing is a great challenge.

Aim: Based on a microsphere fabrication method that relies on injection and surface tension effects, simultaneous demonstration of an array of cavities with precise spacing and sizes is possible where the size of cavities is widely tunable.

Approach: Using a maskless lithography setup, pillars with base and tip diameters of 250 and 60μm are fabricated, which are used for demonstration of microspheres with tunable size, depending on the applied pump pressure. Microcavities composed of Rhodamine B dissolved in glycerol are injected into the polydimethylsiloxane carrier through a nozzle with a diameter of 70  μm.

Results: An ∼4-μJ  /  mm² lasing threshold has been obtained for a laser with a microsphere diameter of ∼350  μm. A redshift originated from the increment of dye concentration has also been observed.

Conclusions: Fabrication of precise microspheres for a microresonator laser is feasible using the introduced method, which can be further generalized using different active materials.