Double-Sided Illumination Grating-Coupled Surface Plasmon Resonance Sensors Using Direct Optical Discs

Commercial optical discs are used as low-cost grating substrates for fabricating grating-coupled surface plasmon resonance (GC-SPR) sensors, and the effects of front-side and back-side illumination are systematically compared. Three different discs were used as grating substrates with grating periods (Λ) of 322 ± 5.2 nm for BD-R, 805 ± 7.5 nm for DVD-R, and 1.582 ± 0.013 µm for CD-R. Silver (Ag) and copper (Cu) films were deposited by magnetron sputtering to form plasmonic gratings. The shallow grating height of BD-R supported continuous metal coverage, while the deeper DVD-R and CD-R grooves resulted in a less continuous layer. Plasmonic responses were measured using wavelength-modulated SPR spectroscopy and predicted with rigorous coupled wave analysis (RCWA). Ag-coated gratings produced sharper and more clearly identifiable resonances than Cu-coated gratings, which exhibited broader due to stronger damping. Front-side illumination produced stronger and more reproducible SPR excitation across all disc types, whereas back-side illumination resulted in more complex spectra as light propagates through the polycarbonate layer. Refractive index sensitivities based using Ag-coated discs of 394, 321, and 290 nm/RIU were obtained for CD-R, BD-R, and DVD-R, respectively. The results clarify the influence of fabrication strategy, illumination geometry, and disc grating geometry on resonance quality and sensitivity in low-cost optical disc-based GC-SPR sensors.