The emergence of co-packaged optics and of parallel optics pluggable form factors with an increased number of fibers poses new challenges for optical packaging technologies. We describe micro-optical interposers manufactured with isothermal glass molding that enable the parallelized connection of large fiber arrays with photonic integrated circuits in a low-rise form factor as well as the management of scrambled light polarization from a remote laser source coupled by single mode fiber. A resonantly assisted but temperature tolerant silicon photonics Mach-Zehnder modulator operated in lumped element configuration is co-developed for that purpose and a concept for a 6.4 Tb/s bi-directional light engine described.
We report on glass-molded micro-optical interposers for single-mode fiber-to-PIC coupling fabricated in parallel by isothermal molding of 1-inch glass plates yielding over 100 arrays of 8 lenses each. Excess losses between PIC and singlemode fiber are below 1 dB. In addition to allowing a narrow package footprint, beam transformation maps mode profiles between fibers and surface couplers, and, in case of grating couplers, can adapt the light incidence angle on a wavelengthspecific basis, facilitating packaging of PICs in CWDM and LAN-WDM modules. The interposers can be further extended to support polarization management and isolation by coating with polarization selective thin film stacks in MacNeille configuration, as well as wavelength multiplexing by coating with dichroic stacks. Using this technique, over 256 bidirectional transceiver channels can be packaged in the footprint of a single reticle.
Laser beam shaping elements can be used e.g. for material processing. The results of these processes can be improved when the usually Gaussian profile of the laser is transformed into a top hat profile, which can be circular or rectangular in shape. Another frequently used type of beam-forming devices are beam splitters for parallel processing using only one laser. These types of beam formers can be implemented as diffractive or refractive elements. So far these optics are produced either directly by means of lithography e.g. in glass or in plastic using a hot embossing process or nanoimprint technology. Elements produced in this way have either the disadvantage of high costs or they are limited in temperature range, laser power or wavelength. A newly developed molding process for glass allows the manufacture of larger numbers of optics with reduced cost.
The production of molds for refractive top hat beam shaping devices requires very high precision of the applied grinding process. Form deviations below 100 nm are necessary to obtain a homogeneous illumination. Measurements of the surface topography of gauss to top hat beam shaping elements using white light interferometry are presented as well as results of optical measurements of the beam profile using a camera.
Continuous diffractive beam shaping elements for beam splitting applications are designed to generate several sub-beams each carrying the same energy. In order to achieve this, form deviations of less than 50 nm are required. Measurements of the surface of a 1 x 5 beam splitter are compared with ideal beam splitter profiles. The resulting beam intensity distribution of a molded element is presented.
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