'Optimizing' splicing processes for optoelectronics assembly in an electronics manufacturing service provider's environment

Optoelectronics technology has been undergoing continuous improvement in order to accommodate widespread customer demand for smaller, faster and cheaper products. This rapid and evolving change in demand is being addressed by using novel material fibers combined with advances in design techniques and processes. One consequence of this rather rapid evolution in technology pertains to challenges vis-a-vis the handling and utilization of fibers during optoelectronics assembly.The focus of this research endeavor is on the processes used to splice fibers during the assembly of optoelectronics devices. The splicing process is the equivalent of soldering in optoelectronics assembly. During splicing, ends of fibers to be connected are fused together using a high electric discharge, such that a minimum amount of signal losses are introduced. It is absolutely critical to have a thorough understanding of relevant factors, such as the type of fiber being used, the parameters being used for the splicing and routing of fibers, and their impact on the reliability of the splice.This research effort addresses the minimization of the losses in optical assemblies and the variability that could result in the manufacturing processes. Optical losses are inherent to an optical assembly. These losses are due to suboptimal splices, improper fiber management, and several other issues such as operator and equipment related variation. Taken together, these factors affect the overall variability of the optoelectronics assembly process.Different types of fibers are used in an optoelectronics assembly. The most common types of fibers are Single Mode Fibers (SMF), Polarization Maintaining (PM) Panda Fibers and Erbium Doped Fibers (EDF). When working with a variety of fibers, it is important to understand the effect of variables that could impact each and every type of fiber. The difference in structure and material can cause each of these fibers to behave in a different way for the same variable. The aim of this research was to develop the process for PM Panda fibers using the fusion splicing process for regular as well as offset (lateral and angular) splicing of the fibers. Given the aforementioned background, research was conducted in the area of fusion splicing. Extensive experiments were conducted on SMFs and PM Panda Fibers with the objective of determining the parameters that significantly affected the splice loss. Statistical methods, such as the Design of Experiments (DOE), were employed to obtain 'optimal' settings for the parameters that minimized the splice losses.During the packaging of fiber optic products, space could be a major constraint for some of the components such as attenuators. Attenuators typically occupy a larger space and could be difficult to package, if required in splice trays. In this regard, studies were conducted to construct the attenuators using an 'offset splicing' technique. Experiments were performed using both the SMF and Panda fibers. 'Optimal' values for significant factors obtained from the experiments conducted for regular splicing served as feeders for performing the offset splicing experiments. This helped in understanding the factors that affect offset splicing as well as obtaining 'optimal' values for those parameters.Based upon this research and the results obtained, recommendations were made for future research opportunities (in-line with the requirements of electronics manufacturing service providers) in the area of fiber optics assembly. These opportunities include (but are not limited to) areas such as fusion splicing, Design for Manufacturing (DFM), component and fiber characterization, and cycle time reduction.Since the advent of fiber optics assembly and test operations in an EMS facility, the research conducted was the first of its kind. This research endeavor took into consideration design and manufacturing constraints, including issues related to fusion splicing, fiber handling, fiber management and variability in the manufacturing of optoelectronics assemblies. These real-life practical considerations (or constraints) were dealt with systematically using statistical methods. Through realistic case studies, this research endeavor enhanced the level of knowledge about the functionality of the optoelectronics assembly process and its variables. The results and findings can be used as an ideal case for similar product families that electronics manufacturing service providers could be manufacturing.In conclusion, the anticipated research effort contributed towards the development of a fundamental understanding of the various factors affecting the splicing of optical fibers from a process and materials perspective for assembly at an Electronics Manufacturing Services (EMS) provider. The unique features of this investigation are the interactions within the process parameters, material properties, and the process conditions during optical assembly.