Simulation & Data Engineering
Design multi-fiber CWDM micro-optic mux-demux
The Challenge
Design a micro-optic multi-fiber CWDM multiplexer and demultiplexer for a 1.2 Tbps, VCSEL-based, socketable optical transceiver.
Achieve very low loss on all of the 48 channels.
Assure crosstalk small enough to not affect the bit error rate.
The optics and optomechanics had to be tightly integrated into the transceiver package and had to address structural issues of the entire package.
Success was only possible if our work was well-coordinated and aligned with multiple teams and subcomponent manufacturers.
The Approach
Evaluate the feasibility of a number of different concepts, evaluating them with respect to fundamental limits, but also taking into account the feasibility, manufacturability, and availability of required subcomponents.
Develop an analytical framework that allows us to explore a large design space and evaluate fundamental tradeoffs.
Implement a simulation strategy that enables optimization for performance, manufacturability, and ease of assembly.
The Work
Implemented a full analytical model that received design parameters as its input, and generated a first order mux/demux design.
Developed a detailed, non-sequential, parametric raytrace model, structured in a way that mimicked the assembly process. The model captured tolerance stack-ups, and allowed accurate sensitivity and Monte-Carlo analysis with over 90 design parameters.
Implemented a simulation orchestration framework and defined system-level performance metrics. This enabled us to quickly evaluate various design choices, and rapidly respond to requests for accommodations from components providers.
Contributed to several patent applications to protect the valuable intellectual property.
The Impact
Gave the client confidence to pursue an aggressive micro-optic architecture grounded in credible performance and manufacturability analysis.
Established a credible technical path that enabled engagement with top-tier suppliers for micro-optic and related component development.
Accelerated development by enabling the team to respond and adapt quickly to design changes, supplier feedback, and manufacturing constraints.
Enabled successful fabrication, optimization, and alpha deployment of the mux/demux and the associated transceiver.