Optical components which transmit light can be made through various processes and materials, such as glass, thermosets, or thermoplastics. These components are then assembled with fiber optic cables and light sources to complete the full optical assembly. This potential mixture of different types of materials can impact dimensional position of various alignment features needed for low signal loss. In this paper, we show the beneficial or detrimental effects of mixed materials and component design on dimensional alignment in optical assemblies. For assembly, solder reflow capable thermoplastic resins are evaluated and compared to other commercially available material classes in ease of assembly, design, and performance parameters.
Thermoplastic polyetherimides (ULTEM™ and EXTEM™ resins) have been used to produce complex optical lenses and ferrules that are integrated in optical interconnect sub-assemblies. Current thermoplastic optics must be added separately to prevent dimensional changes from the 260°C peak temperature of a solder reflow process. This paper covers injection molding parameters and solder reflow conditions that influence optical properties and dimensional stability of solder-reflowable test components.
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