3D printed fiber sockets for plug and play micro-optics

Abstract

Integrating micro-optical components at the end facet of an optical fiber enables compact optics to shape the output beam (e.g. collimating, focusing, and coupling to free space elements or photonic integrated circuits). However, the scalability of this approach is a longstanding challenge as these components must be aligned onto individual fiber facets. In this paper, we propose a socket that enables easy slotting of fibers, self-alignment, and coupling onto micro-optical components. This integrated socket can be detached from the substrate upon fiber insertion to create a stand-alone optical system. Fabrication is done using nanoscale 3D printing via two-photon polymerization lithography onto glass substrates, which allows multiple sockets to be patterned in a single print. We investigated variations in socket design and evaluated the performance of optical elements for telecom wavelengths. We obtained an alignment accuracy of ∼3.5 µm. These socket designs can be customized for high efficiency chip to fiber coupling and extended to other spectral ranges for free-form optics.

3D Printing Mesoscale Optical Components with a Low-Cost Resin Printer Integrated with a Fiber-Optic Taper

“…A promising approach was introduced in 29 where linear stages and galvanometric scanners are synchronized to allow for continuous scanning. While this technique achieves a stitch-free printing with a structuring rate of 5600 μm 3 /s, TPL exhibits a print rate of 1.89e + 6 μm 3 /s (0.00189 mm 3 /s) in the swift print mode where structures are printed with shell and scaffold instead of printing solid structures 30 with a limited print field of 1000 μm diameter. In contrast to these point-by-point printing techniques, resin printers use layer-by-layer structuring to create 3D models.…”

Micro‐Optics 3D Printed via Multi‐Photon Laser Lithography

“…Several different combinations of waveguide facets and coupling elements proved the high reproducibility of the low coupling loss of the devices. 3D‐printed fiber sockets were proposed for plug‐and‐play micro‐optics, exploiting the LDW fabrication flexibility and reducing the alignment issue [ 168 ] This was proven for telecom wavelengths, but it is likely that it will be extended to different platforms and for various applications.…”

Integrated Photonics Packaging: Challenges and Opportunities

“…Further improving alignment tolerance requires expansion of the fiber mode via micro-optics , at the expense of angular tolerance or using a pair of curved mirrors to steer the reflected beam direction and compensate for misalignment . Alternatively, passive mechanical alignment features can be incorporated to relax the alignment accuracy without modifying the optical design. ,, A different approach that has shown potential in relaxing alignment tolerances is that of photonic wire bonding. − The ability to correct for 3D misalignments by arbitrarily defining the path each wire will follow naturally holds various advantages and has already started being commercialized (e.g., Vanguard Photonics GmbH). The wires are normally encased in a low index polymeric cladding, which serves the double purpose of reducing bending losses and improving the mechanical stability of the wire. , With that said, there are still some disadvantages in the technology, including the reduced efficiency when using cladded waveguides and the requirement for customized TPP printing for each photonic link.…”

“…59 Alternatively, passive mechanical alignment features can be incorporated to relax the alignment accuracy without modifying the optical design. 16,60,61 A different approach that has shown potential in relaxing alignment tolerances is that of photonic wire bonding. 62−65 The ability to correct for 3D misalignments by arbitrarily defining the path each wire will follow naturally holds various advantages and has already started being commercialized (e.g., Vanguard Photonics GmbH).…”