Laser welding of fiber array units.

Area of Science:

• Photonics and Optical Engineering
• Materials Science and Engineering
• Manufacturing Technology

Background:

• Traditional fiber array unit (FAU) connector fabrication often relies on expensive V-groove plates for fiber alignment.
• Achieving robust glass-to-glass bonds and precise fiber placement is critical for high-performance optical interconnects.
• Minimizing epoxy usage and ensuring material compatibility are key challenges in miniaturized optical packaging.

Purpose of the Study:

• To develop an alternative fabrication method for fiber array unit (FAU) connectors using near-infrared (near-IR) laser welding.
• To demonstrate the feasibility of achieving strong glass-to-glass bonds without V-groove plates.
• To evaluate the impact of epoxy properties on the long-term reliability of the fabricated FAU connectors.

Main Methods:

• Fabrication of fiber array units (FAU) utilizing a near-IR laser welding process.
• Deposition of a thin metal film on planar glass substrates to enhance laser absorption for localized heating.
• Assembly using low coefficient of thermal expansion (CTE) epoxies for minimal structural support and environmental protection.

Main Results:

• Successful implementation of near-IR laser welding for precise fiber locking and strong glass-to-glass bonding.
• Elimination of the need for expensive V-groove plates, while maintaining high fiber placement accuracy.
• Minimized epoxy application, primarily for macro-component securing and environmental sealing, contributing to long-term reliability.

Conclusions:

• Near-IR laser welding offers a cost-effective and accurate method for fabricating fiber array units (FAU).
• The developed process ensures robust optical connections with enhanced long-term reliability due to optimized material selection and minimal epoxy use.
• This technique presents a viable alternative for high-precision optical packaging in demanding applications.