Optical performance of low-cost self-aligned MCM-D based optical data links

We discuss the details of the design and performance of the optics proposed for a MCM-D based low-cost multimode optical data link. The optical system is completely self-aligned, taking advantage of flip-chip bonding, solder-bump self-alignment, mechanical self-alignment using silicon micromachining, and precision plastic components. Preliminary results demonstrate that the integral-lens design of the opto electronic device significantly effects the coupling efficiency and the requisite tolerances of the components that comprise the coupling optics. We show that coupling efficiencies of 70% or better are readily achievable with piece parts made using standard practices. These coupling efficiencies compare favorably with those in actively-aligned optical subassemblies used in current optical data link products.