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Laser Cleaving of Optical Connectors

Laser Cleaving of Optical Connectors. Didi Hachnochi VP Engineering & R&D Duane Dinkel President Sagitta Incorporated 655-H Fairview Road Simpsonville, SC 29680. Introduction. The Problems Mechanical cleaving – operator and tool-dependent quality (hand-scribe, sand-blasting, etc.)

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Laser Cleaving of Optical Connectors

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  1. Laser Cleaving of Optical Connectors Didi Hachnochi VP Engineering & R&D Duane Dinkel President Sagitta Incorporated 655-H Fairview Road Simpsonville, SC 29680

  2. Introduction • The Problems • Mechanical cleaving – operator and tool-dependent quality (hand-scribe, sand-blasting, etc.) • Epoxy Bead size – operator and process-dependent quality • Polishing – sub-optimal initial conditions (overuse of consumables; costly) • Connector/Fiber-specific challenges – MT, Large OD fiber, SMA’s, etc. • Compromised First Pass Yield, Throughput, Quality, and Cost! • The Solution • Laser Cleaving (integrated denubbing and epoxy removal) • Results • Future Technologies • Conclusion

  3. Cut to Length Strip & Clean Assembly I Insertion Into ferrule Epoxy Application Epoxy Cure Fiber Cleave Air Polish “Denub” Epoxy Removal Polish Sequence Assembly II Clean Endface Visual Inspection Geometry Inspection Optical Inspection Label And Pack Connector Termination Process

  4. Uncleaved Connector Tip Ceramic Ceramic Ferrule Ferrule 300-1200um 5-15 mm 5.0 – 15.0mm Epoxy Epoxy Bead Bead Fiber Fiber “ “ Stinger Stinger ” ”

  5. Manual Cleave Process Mechanical techniques represent > 90% of the industry

  6. Hand Polish Process – “Denubbing” Before After 300 – 500 um 300 – 300 – 1200 um – 1000um Fiber Stub & Fiber Stub & Coarse Hand Coarse Hand Epoxy Bead Epoxy Bead Polishing Material Polishing Material Hand polishing can consume up to 30 sec per end

  7. Manual Cleave – The Problems • Variable Epoxy Bead Size • Polishing process variable • Requires hand polish to remove • Variable “Stinger” Length • Extra polishing step Epoxy Bead Size Range Height: 300 - 1200um Volume: 0.02 – 0.05 mm3 Cleaved Fiber Range 300 – 500um • Poor Cleave = Bad Endface • Yield (and quality) problem ⇨ reworks! • Core cracks • Endface chips

  8. Laser Cleaver Animation

  9. Into Polishing 80 – 120um Focused CO2 beam spot passes thru fiber and epoxy Laser Cleaving Principal Combines Cleaving + Denubbing + Epoxy Removal From Curing Ceramic Ferrule 300 – 1200um 5.0 – 15.0mm Epoxy Bead Fiber “Stinger”

  10. Simplex Connector Before/After Cleave Small epoxy bead Large epoxy bead Before Cleave Hand Cleave Bellow epoxy! After Laser Cleave Laser Cleave Fiber stub & residual epoxy < 100μ

  11. Cleave Height Reproducibility USL TGT LSL Field Performance - Simplex Limits must be sufficient to eliminate polishing steps

  12. Ferrule Before MT Connector Cleaving Progress Epoxy 12 Fibers After 2 cycles After 4 cycles

  13. Field Performance - MTP • Maximum fiber variation < 20um • Demonstrated ability to remove 20mm3 (5mm x 2mm x 2mm) of epoxy bead • Cleave height adjustable from 50um • Only constraint is in molded ferrule tolerance (specified at +/- 50um)

  14. Laser Cleaving Implementation • Laser safety compliance • Ergonomics • Ferrule size (1.25mm vs. 2.5mm vs. MT, etc.) • Fiber type – SM vs. MM • Process flow • Violation of intellectual property

  15. Quality Benefits of Laser Cleaving • Eliminates operator and tool dependent cleave quality • Simplifies the polishing process & removes interdependencies • Eliminates cleave related multimode fiber “core cracking” • Improves connector reliability - laser “tempers/anneals” fiber endface relieving inherent fiber stresses Removes up-stream variability “Levels the process playing field”

  16. Cost Benefits of Laser Cleaving Combines scribing + denubbing + epoxy removal • Reduces consumable costs • Minimizes abrasive consumable cost (1-2 polishing operations eliminated) • Eliminates scribe blade wear-out • Higher yields • Reduces headcount (or increases throughput)

  17. Cost Benefits of Laser Cleaving Labor ⇩ Cost of Consumables ⇩ (abrasive films, scribes, etc.) Yields ⇧ COGS reduces by 5 – 10% (Shaving $50M annually out of industry costs)

  18. Enabling Benefits of Laser Cleaving • Cleaves fiber types that are not readily mechanically cleaved • Accommodates large OD and specialty fibers • Suitable for MTP production

  19. Field Data • Field Observations and Comments • Laser cleaving removes operator dependence – excellent repeatability between shifts, minimizes training • Laser cleaving removes upstream epoxy bead variability – reduces polishing steps • Laser cleaving decreases manufacturing costs – 2x throughput, improves yield

  20. Image Acquisition & ProcessingExtending the Capability 1. Raw data image 3. Image processing – Best fit to edge 2. Image processing – Edge 4. Best edge fit on original image Enables automating the laser cleaving process

  21. Extensions of Laser Cleaving Technology • Field Module • Single Step Polishing Support Module • Fully automated platform Cleaving + Polishing + Cleaning + Inspection

  22. Conclusion • Advantages of Laser Cleaving • Increased Quality & FPY • Faster – eliminate polishing process steps • Cheaper – lower process cost, less rework • Reliable – no detrimental impact • Field scalable • Enables Single Step Polishing • Disadvantages • None, of course

  23. Thank You!

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