The microjet printing method is being used to fabricate microlens arrays for use in massively parallel, VCSELbased datacom switches and to deposit lenslets of various configurations onto the tips of single-mode telecom fibers. Applications in the latter case include collimation ofthe output beams for free space optical interconnection and increasing the fiber numerical aperture for collection of light from edge-emitting diode lasers. Additional applications ofthis technology include printing of arrays of active sensor elements onto the tips of imaging fiber bundles and fabrication of microlenses with axial index of refraction gradients to reduce focal spot size, utilizing multiple print heads with differing fluids. This low-cost, data-driven process, based on "dropon-demand" inkjet technology, involves the dispensing and placing of precisely sized microdroplets of optical material onto optical substrates. The micro-optical elements are printed with 100% solid, UV-curing optical epoxies, utilizing printing devices that can dispense picoliter-volume droplets at temperatures up to 300°C.
The technology for fabricating micro-optical elements for low cost optical interconnects by micro-jet (ink-jet) printing has been under development for over two years [1,2]. This data-driven method of micro-optics fabrication offers the benefits of low cost, flexibility and in-situ, non-contact processing. These features can be used to advantage in applications where increasing the efficiency of optical power coupling as a value-added step is a goal, and they provide unique capabilities for rapid prototyping and customization of microlens arrays. Here we present our latest results in developing this Optics-Jet technology for applications such as collimation of the outputs of LEDs and diode lasers, as well as for increasing the efficiency of focusing of GRIN lenses [3]. Data on printed microlens optical characteristics will be shown, as well as their performance in collimation and astigmatism reduction of optical sources.
In this paper we present different configurations for a compact free-space optical interconnection (FSOI) module by combining two radial gradient refractive index lenses (GRIN) and/or two arrays of refractive microlenses. Based on our findings with ray-tracing and radiometric analysis we discuss how we have selected the proper optical system configurations and how we have chosen the different design parameters to optimally accommodate different types of opto-electronic emitters such as LEDs, micro-cavity LEDs and VCSELs. We hereby focused on maximizing optical coupling efficiencies and misalignment tolerances while minimizing inter-channel cross-talk. Furthermore we discuss the experimental optical characteristics of two such prototype modules that we completed together with the first experimental results of their use in parallel data communication demonstrator systems.
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