Building blocks for actively-aligned micro-optical systems in rapid prototyping and small series production

In recent years there has been considerable progress in utilizing fully automated machines for the assembly of microoptical systems. Such systems integrate laser sources, optical elements and detectors into tight packages, and efficiently couple light to free space beams, waveguides in optical backplanes, or optical fibers for longer reach transmission. The required electrical-optical and optical components are placed and aligned actively in more than one respect. For one, all active components are actually operated in the alignment process, and, more importantly, the placing of all components is controlled actively by camera systems and power detectors with live feedback for an optimal coupling efficiency. The total number of optical components typically is in the range of 5 to 50, whereas the number of actors with gripping tools for the actual handling and aligning is limited, with little flexibility in the gripping width. The assembly process therefore is strictly sequential and, given that an automated tool changing has not been established in this class of machines yet, there are either limitations in the geometries of components that may be used, or time-consuming interaction by human operators is needed. As a solution we propose and present lasered glass building blocks with standardized gripping geometries that enclose optical elements of various shapes and functionalities. These are cut as free form geometries with green short pulse and CO2 lasers. What seems to add cost at first rather increases freedom of design and adds an economical flexibility to create very hybrid assemblies of various micro-optical assemblies also in small numbers.