In this work, we developed a new mould fabrication technique to prepare a novel solid state dye laser gain medium with sandwich structure. Using the core of dye doped TEOS-GPTMS system ORMOSIL gel glass, and the moulds consisting of two optical coated K9 glasses with the thickness of 1mm, we obtained this composite laser gain medium. Comparing with the same laser gain medium without moulds by conventional method, the laser performance of this resulting medium has been greatly improved: the laser life time increases by 1 order of magnitude, the slope efficiency increases 12% and the laser threshold decreased 5%. Further reformations on laser pumping device made the composite solid state dye laser nearly reach practical levels.
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