Fast active alignment in photonics device packaging

Of the many areas that are being addressed to reduce packaging costs in photonics, the process of aligning and attaching fibers and micro-optical components in the package is still regarded as one of the most expensive and time consuming. This paper reports on recent work in significantly reducing the overall cycle time for active optical alignment, utilizing a combination of modified automation algorithms and upgraded firmware and software on existing automation tools. A novel "fast alignment" technology is introduced and cycle time reductions of between 60% and 80% are reported for several relevant applications, including direct coupling with a lensed fiber and indirect coupling with a ball lens and a fiber. The cycle time effects of coupling geometry, initial process set-up conditions, and other process parameter sensitivities are also discussed.