Automated mass production line for optical module using passive alignment technique

Since the growth of fiber optic communications, extremely low cost optical modules have been expected to be realized. Particularly for the subscriber applications and local area networks (LANs), less than half of past module cost is required. In accordance with the spread of fiber optic transmission, higher volume manufacture is also needed. To attain both of low cost and high productivity, we developed passive alignment technique and optical coupling structure that is suitable for automatic assembly. We also developed automatic assemble equipment for producing several types of optical modules. To reduce optical module cost, it is important to cut down the assembly cost and expensive parts such as optical lens. The passive alignment technique brings us to realize easy assembly of modules and minimize the constructed components of optical coupling. Our mass production techniques include not only for optical coupling but also packaging of the module. We have several types of optical modules according to different fiber communication systems; there are laser modules, detector modules, optical interface modules that are integrated optical coupling and electrical circuit, and PLC (Planar Lightwave Circuit) modules that are integrated passive component. Basically all modules have same optical coupling structure and keep the design rules for automatic assembly. Accordingly, we can use the same equipment for the same assembly process. In this paper, we will introduce basic assembly process and our mass production line for optical coupling and packaging by using passive alignment technique.