Precision Optical Alignment Block Molding Research

In order to reduce paekaging requirements for advanced optical and optoelectronic components and system elements and improve the rate of new high performance optical system implementation, an innovative new technology for extremely highprecision plastic injeetion molding will be developed. This research will establish a method by which precision polymeric substrates may be formed to allow critical optical alignment to be obtained in a simple, light, low-cost technique that will provide a reliable method of producinr integrated optoetectronic circuits for high speed computational and communications systems. The goal of this initialdevelopment will be a polymeric alignment block with good dimensional stability and micron accuracies of position across an array of optical fibers. We propose to conduct this Phase I work on the development of precision molded fiber alignment blocks by working in 4 specific critical areas: 1. Precision mold development, 2. Materials selection and optimization, 3. Precision injection molding equipment design, 4. Molding parameter optimization. This research will provide the needed foundation for precision injection molding of plastic materials to form highly accurate, dimensionally stable, low-cost optical integration substrates for high speed computation and communications systems. First commercial products are anticipated to be passive alignment substrates for optical integrated assemblies.