Laser to single-mode fiber assembly using an electroforming technique

One of the most difficult problems in coupling laser diodes to single-mode fibers is maintaining alignment while the two components are locked into place. The authors report a novel approach to the lockup process that uses electroforming. This technique solves the isolation and train relief problem by locking the laser and fiber into a single structure rather than by mounting both to a common base. With this novel technique and simple butt coupling, coupling efficiencies as high as 14% have been achieved with very little alignment shift during lockup. The completed structure is at least 100 times smaller in volume than conventional packages and provides strain relief and isolation from mechanical disturbances.<>