As 400G/800G and even 1.6T high-speed optical modules, CPO, silicon photonics and high-speed optical engines move toward volume production, the optical coupling step imposes higher demands on equipment precision, consistency and automation. The automatic coupling machine for optical modules is an integrated coupling production system built for this demand. Through the coordination of a nanometer motion stage, a vision system and in-house algorithms, it completes the full workflow from end-face inspection to curing, fully replacing manual coupling.
1. Why High-speed Optical Modules Need Active Alignment
In a high-speed optical module, the optical signals between the lens, the fiber array and the waveguide chip must be precisely aligned to achieve ideal coupling efficiency and controllable return loss. Passive alignment is limited by accumulated device tolerances and fixturing errors and can hardly meet the optical requirements above 400G. Active alignment, which measures optical power in real time, drives the motion stage under electrical feedback to search for the peak intensity and then fixes the position, has become the mainstream method for securing optical performance in high-volume production of high-speed devices.
2. Building Blocks: Nanometer Stage, Vision System and In-house Optimization Algorithm
The machine consists of three cooperating parts. The first is a ±50nm high-precision nanometer motion stage that provides sub-wavelength positioning. The second is a high-performance vision inspection system that checks the device end face during loading and unloading. The third is a mature in-house intelligent coupling optimization algorithm that quickly searches for and converges to the coupling peak. Working together, these elements allow the machine to replace manual coupling and eliminate operator-induced deviation.
3. Full Workflow: End-face Inspection, Peak Search, Alignment, Dispensing and Curing
At the loading stage, the machine first inspects the device end face to screen out abnormal parts. It then automatically enters optical peak searching, driving the stage under optical-power feedback toward the optimal position. After precise alignment near the peak, dispensing is performed and the process moves on to curing. The coupling process logic is freely editable and the software interface is customizable, keeping setup and commissioning short. According to the product page, the machine delivers a stable coupling yield above 97% and an equipment uptime above 93%.
4. Dual-process Compatibility: Dual-lens and Dual-FA
Given the parallel technical routes in the industry, the integrated platform supports both mainstream coupling processes, dual-lens and dual-FA, and both have already been deployed in production. The machine can adapt to different package forms such as COB, BOX and optical engines, as well as to single-mode and multi-mode devices and various optical communication components including lenses, FAs, MUX and DMUX.
5. Closed-loop Control of Key Optical Metrics
During dispensing and curing, the machine applies closed-loop control over key optical metrics such as glue-layer thickness, planarity and return loss. This keeps the optical performance of batch products consistent and the return loss controllable, thereby securing production consistency while reducing defect rate and manufacturing cost.
6. Flexible Modular Architecture
The machine adopts a flexible modular architecture, enabling quick and convenient changeover and strong expandability to support multi-category, multi-spec products. It covers enterprise R&D sampling, small-to-medium batch trial production and large-scale standardized volume manufacturing. Shenzhen Xingte Technology Co., Ltd. has long focused on the research, development and manufacturing of optical communication intelligent equipment, and provides stable automatic coupling solutions for high-speed optical module production.
