Demcon Photonics is developing a manufacturing approach that uses laser-written optical waveguides to connect fiber arrays to photonic chips. Instead of precisely positioning the fibers to match the chip’s optical interfaces, the approach adapts the connecting light paths to their actual positions. The company is working on prototypes and plans to present a demonstrator to potential partners in early 2027.
Today, connecting fiber arrays to photonic integrated circuits requires active alignment: Light is sent through the connection while the array is moved until optical coupling is optimized. This is a relatively slow process, creating a bottleneck for photonics scaling. Additionally, variations within the array mean that aligning one or a few fibers doesn’t necessarily bring every fiber into the optimal position.
Demcon’s approach uses computer vision to measure the positions of the individual fibers and the chip’s optical interfaces. Femtosecond laser pulses then locally modify the refractive index of glass, writing waveguides that guide light between the corresponding connections. Each light path can accommodate differences in position, reducing the need for precise mechanical alignment of the entire array. The precision requirement therefore shifts from mechanically positioning the components to measuring their interfaces and writing the connecting waveguides.
Demcon Photonics will act as a system integrator, combining commercially available direct laser writing technology with its expertise in optomechatronics, metrology and production equipment. It’s seeking technology developers ready to move from the laboratory to the factory, as well as photonics manufacturers needing production equipment. The aim is to develop a proven industrial solution that makes optical connections a high-volume assembly process comparable to wire bonding.
