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Effect of Assembly and Optical Design Tolerances on Process Robustness and Manufacturing Yields in Laser Packaging

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Abstract

An important function of the laser packaging process is coupling of the laser beam into a single mode fiber. To achieve this, the laser chip, optical components (such as lenses) and fiber are positioned relative to each other and fixed using various techniques such as epoxy or solder bonding, mechanical press fits, resistance welding and laser welding. The design of the optical system determines the optimal locations of these components (for maximizing the coupling efficiency). It also determines how the coupling efficiency (CE) degrades with deviations in the locations of these components. These deviations occur during manufacture due to mechanical tolerances on pieceparts, positioning errors and movements associated with the fixing process. They could also occur during operation of the device at varying temperature (tracking) or due to relaxation of joints over time (stability).

© 1995 Optical Society of America

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