Unlocking the Potential of Photonic Integrated Circuit (PIC) Testing: Bridging the Gap to Mass Manufacturing

Rajesh Uppal March 7, 2024 Manufacturing, Photonics Comments Off on Unlocking the Potential of Photonic Integrated Circuit (PIC) Testing: Bridging the Gap to Mass Manufacturing 131 Views

The world of integrated photonics technology is on the brink of a revolution, promising smaller, faster, and more efficient devices for a range of applications. Photonic Integrated Circuits (PICs) are at the forefront of technological innovation, poised to transform diverse industries ranging from data communications to biomedical applications. However, the transition from lab to high-volume manufacturing is not without its challenges. In this article, we delve into the complexities of PIC testing and the pivotal role played by AIM Photonics, with a focus on their advanced testing services.

Silicon Photonics: A Rising Star

Silicon photonics, an innovative technology that blends silicon chips with optical components like lasers, offers a host of advantages. It facilitates high-speed data transmission, reduced latesncy, extended transmission distances, and reduced power consumption, all by leveraging the power of light instead of traditional electrical signals.

The Complexity of PIC Testing

PICs are intricate devices, housing thousands, if not millions, of individual photonic components. This intricate web of components makes them a formidable challenge to test using traditional methods, particularly considering their heightened sensitivity to defects. These factors combined lead to time-consuming and meticulous testing processes.

Testing integrated photonic circuits is a complex task that surpasses the capabilities of conventional electronic device testing tools.

Precise Fiber/Optical Alignment: PICs require pinpoint alignment to couple light with external fibers, demanding sub-micron precision due to the components’ minuscule size.
Power Limitations: Photonic circuits operate within stringent power budgets, necessitating testing without introducing significant power losses or signal degradation.
Packaging and Integration: The integration of photonic chips into practical devices requires meticulous packaging techniques to enable efficient light signal coupling, impacting circuit performance.
Polarization Control: PIC tests often mandate precise polarization control along the signal path, given that integrated photonic components are optimized for specific input and output polarization states.
RF Signal Integrity: Measuring RF signals accurately and accounting for de-embedding up to the device boundary is a substantial challenge, with signal quality hinging on layout and susceptibility to parasitic coupling.
Manufacturing Variations: Estimating circuit performance across multiple dies requires understanding expected manufacturing variations and the correlation between component and circuit-level parameter variation.

Recent Strides in PIC Testing

In the quest for efficient PIC testing, several pioneering breakthroughs have emerged:

Machine Learning-based PIC Testing: Harnessing the power of machine learning, innovative algorithms are being developed for PIC testing. These algorithms analyze substantial data sets from PICs to identify patterns indicative of defects. For instance, researchers at the University of California, Berkeley have crafted a machine learning algorithm boasting a remarkable 99% accuracy rate in detecting PIC defects.
Optical Coherence Tomography (OCT) for PIC Testing: OCT is a non-destructive imaging technique that constructs intricate three-dimensional images of PICs. This method provides invaluable insights into identifying defects such as cracks and voids. Researchers at the University of Southampton, for instance, have pioneered an OCT system capable of real-time PIC testing.
Optical Spectroscopy for PIC Testing: Optical spectroscopy offers a powerful tool to measure the optical properties of PICs, including wavelength transmission and reflection. These measurements validate PIC performance and detect any aberrations with high precision. At the Fraunhofer Institute for Applied Optics and Precision Engineering, researchers have developed an optical spectroscopy system designed for accurate PIC testing.

AIM Photonics, a key player in this field, is pushing the boundaries of integrated photonic circuit (PIC) design and development.

AIM Photonics’ Opto-electronic Testing Services encompasses a comprehensive toolset for passive optical, active optoelectronic, telecom/datacom, RF, and DC testing. Among these tools is a 300mm automated electro-optic wafer and die level prober, boasting six degrees of optimization for vertical and edge-coupler-based measurements. Additional tools include tunable lasers at the CL and O-band, laser characterization (LIV, gain, and linewidth), and small signal high-frequency measurement tools for MMIC applications.

Future upgrades to AIM Photonics’ test infrastructure will expand electro-optic s-parameter measurements to 110 GHz, as well as introduce capabilities for shorter-wavelength measurements. This enhancement ensures that AIM Photonics remains at the forefront of PIC testing technology.

AIM Photonics serves as a critical resource for both small businesses and large organizations involved in research and development, offering access to cutting-edge test and measurement tools that may be cost-prohibitive for many. The institute’s expertise and infrastructure are instrumental in facilitating partnerships with organizations like NASA, where AIM Photonics evaluates photodetector and modulator performance for spaceflight LiDAR systems.

As one of nine Manufacturing Innovation Institutes established by the U.S. Department of Defense, AIM Photonics’ charge is to build a complete manufacturing ecosystem that will enable the affordable and rapid transition of this relatively new technology into products and systems that help secure national defense and economic priorities.

Additionally, AIM Photonics collaborates with industry leaders such as L3Harris, focusing on reducing the size, weight, and power of multi-channel optical systems. The institute’s advanced testing services validate the manufacturability of prototype devices, streamlining the design, fabrication, packaging, and testing cycle.

The Road Ahead

The recent breakthroughs in PIC testing are merely the tip of the iceberg, as ongoing research continues to drive innovation. Some promising areas of research include:

On-chip Testing: The integration of test circuits onto the PIC itself is a pioneering approach. This method enables real-time testing of PICs without the need for external test equipment.
Wafer-scale Testing: This innovative approach involves testing all PICs on a wafer simultaneously, drastically reducing testing time and costs.
Artificial Intelligence (AI)-based PIC Testing: Leveraging AI, researchers are developing advanced PIC testing algorithms that outperform traditional methods in both accuracy and efficiency.

The development of new and improved PIC testing methods is pivotal to mass-producing PICs. By streamlining testing processes and ensuring rapid, reliable testing, these advancements will contribute to reducing the cost of PICs and enhancing their accessibility across an even broader spectrum of applications. The era of PICs is just beginning, and the future holds the promise of even more innovative and efficient testing methods.

References and Resources also include:

https://www.techbriefs.com/component/content/article/tb/supplements/pit/features/articles/48907