Optical performance of low-cost self-aligned MCM-D based optical data links

We discuss the details of the design and performance of the optics proposed for a MCM-D based low-cost multi-mode optical data link. The optical system is completely self-aligned taking advantage of flip-chip bonding, solder-bump self-alignment, mechanical self-alignment using silicon micromachining, and precision plastic components. Preliminary results demonstrate that the integral-lens design of the optoelectronic device significantly effects the coupling efficiency and the requisite tolerances of the components that comprise the coupling optics. We show that coupling efficiencies of 70% or better are readily achievable with piece parts made using standard practices. These coupling efficiencies compare favorably with those in actively-aligned optical subassemblies used in current optical data link products