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To detail results of research into optical waveguides fabricated from silicon on insulator (SOI) for on‐chip high speed applications and from polymer for more general applications.

This paper shows the processes for wet etch fabrication of SOI single mode rib waveguides including compact crystal plane turning mirrors. Losses for the mirror facets are determined by difference measurements. Multimode polymer strip waveguides are fabricated on glass substrates by conventional photolithography using SU8 polymer and tested for attenuation.

Fabrication of compact turning mirrors for silicon waveguides requires precise alignment of masks and controlled etching of the corner facets in order to obtain correct alignment of the mirror face with the incoming and outgoing waveguides. Measurements of losses per mirror facet show typical losses of 1‐2 dB/facet. Suggestions for improvements are made. Preliminary results for polymer waveguides show the necessity for high quality lithography.

Optical interconnects for high speed communication on board and on chip are part of the ITRS Road Map for advanced interconnects. Design of optical elements to enable this, including reduction of on‐chip area by turning mirrors, is necessary for on‐chip optical technology to be successful. Compact etched mirrors described here extend previous designs and enable fabrication at any position on‐chip. New etch mask techniques for silicon waveguide fabrication are also described.

To investigate the influences of environmental stresses on board‐embedded polymeric waveguides.

Optical multimode waveguides were embedded on printed circuit boards using commercial polymers. The optical‐PCBs varying in board structure and in optical build‐up materials were exposed to heat, moisture and ionic‐contaminants in accelerated reliability tests. The influence of stress factors on the structural integrity and functional parameters, namely the refractive index and optical transmissivity, was investigated at the key communication wavelengths.

Isothermal annealing reduced the refractive index to the greatest extent. The optical‐PCB structure with an optical surface build‐up layer was observed to be more vulnerable under temperature shock when compared with the optical‐PCB with optical inner layer. The buffer layer beneath the optical build‐up was found to improve the stability of the optical waveguides significantly. The results indicated of wavelength dependence to the aging factor with a failure mechanism. The factors affecting the performance and reliability of polymer‐based optical waveguides on PCBs were discussed.

More experimental data and investigations of failure mechanisms are required to ultimately obtain sufficient reliability statistics for accurate life‐time prediction models.

Optical interconnects are seen as a promising solution to overcome performance limitations encountered with high‐frequency electrical interconnections. As an emerging technology, only a limited amount of reliability data on optical/electrical packages is available. The paper investigates the influences of environmental stresses on board‐embedded polymeric waveguides.

The purpose of this paper is to study fabrication of optical‐PCBs on panel scale boards in a conventional modern PCB process environment. It evaluates impacts on board design and manufacturing with the developed optical board verifiers outlining challenges and requirements for manufacturing low‐loss waveguide structures and optical building blocks. The study aims to expand the current knowledge in the field by adding results obtained by utilizing industrial production infrastructure and developed scalable manufacturing processes to fabricate optical‐PCBs and board assemblies in high‐volumes and low‐cost manner.

Impacts on board design and manufacturing were studied with the developed optical technology verifiers. One verifier is optical‐PCB with embedded waveguides, integrated i/o couplers and optical vias. Another verifier is large size PCB with optical layer. A system‐level optical board assembly with 12.5 Gb/s Tx/Rx devices on surface mounted ball grid array (BGA) modules is designed for optical link analysis. Fabricated optical structures on verifiers are evaluated of their physical characteristics utilizing optical, SEM, LSCM analysis methods. Performance testing is conducted using standard optical transmission measurement methods and equipment.

The paper provides empirical results about fabrication of multimode optical waveguides with conventional PCB process equipment. Results suggest that current coating and imaging equipments are capable of producing optical waveguide patterns with high resolution and size accuracy. However, fabricators would require larger process window and defect tolerance for processing optical materials to obtain low‐loss waveguides with sufficient yields.

Because of the limited amount of design variants in production verifiers evaluated in this paper, some impacts like effect of base material, board construction, optical layer location and beam coupling solution were not evaluated. Likewise, impacts on long‐term stability and cost were not addressed. These factors however require further investigation to address technical feasibility of optical PCBs technology prior commercial high volume production.

The paper includes implications for the development of a fabrication methods and testing procedures for optical polymer waveguide layers on PCBs.

This paper fulfils need to provide results on design, fabrication and characterization of optical PCBs and backplanes from industrial fabricator's perspective. The paper provides input for end‐user and developers to evaluate technical performance, robustness, and maturity of building blocks and supply chain to support polymer waveguide based technology for intra‐system optical links.

High density interconnect (HDI) printed circuits are now being designed in ever‐increasing quantities for very high‐speed applications. The challenge of opto‐electronics and integration of photonics into the printed circuit has started to take off. In the next 7 years, expectations are that photonic printed circuit boards will grow to a $2.5 billion industry. This paper looks at the issues, materials and current processes being researched by European, Japanese and North American organizations to create this integrated opto‐electronic circuit board. In addition to reviewing the global players in polymer photonics, this paper will review the current programs of four of the six groups globally, namely EOBC‐OptoFoil (University of Ulm, Fraunhafer Inst., Daimler‐Chrysler, Siemens), PolyGuide (Dupont, HP), TOPCat (NIST, 3M, Goodyear), Truemode™ (Terahertz), NTT and JIEP.

There has been increasing interest in the development of printable electronics to meet the growing demand for low‐cost, large‐area, miniaturized, flexible and lightweight devices. The purpose of this paper is to discuss the electronic applications of novel printable materials.

The paper addresses the utilization of polymer nanocomposites as it relates to printable and flexible technology for electronic packaging. Printable technology such as screen‐printing, ink‐jet printing, and microcontact printing provides a fully additive, non‐contacting deposition method that is suitable for flexible production.

A variety of printable nanomaterials for electronic packaging have been developed. This includes nanocapacitors and resistors as embedded passives, nanolaser materials, optical materials, etc. Materials can provide high‐capacitance densities, ranging from 5 to 25 nF/in², depending on composition, particle size, and film thickness. The electrical properties of capacitors fabricated from BaTiO₃‐epoxy nanocomposites showed a stable dielectric constant and low loss over a frequency range from 1 to 1,000 MHz. A variety of printable discrete resistors with different sheet resistances, ranging from ohm to Mohm, processed on large panels (19.5×24 inches) have been fabricated. Low‐resistivity materials, with volume resistivity in the range of 10⁻⁴‐10⁻⁶ ohm cm, depending on composition, particle size, and loading, can be used as conductive joints for high‐frequency and high‐density interconnect applications. Thermosetting polymers modified with ceramics or organics can produce low k and lower loss dielectrics. Reliability of the materials was ascertained by (Infrared; IR‐reflow), thermal cycling, pressure cooker test (PCT) and solder shock testing. The change in capacitance after 3× IR‐reflow and after 1,000 cycles of deep thermal cycling between −55°C and +125°C was within 5 per cent. Most of the materials in the test vehicle were stable after IR‐reflow, PCT, and solder shock.

The electronic applications of printable, high‐performance nanocomposite materials such as adhesives (both conductive and non‐conductive), interlayer dielectrics (low‐k, low‐loss dielectrics), embedded passives (capacitors and resistors), and circuits, etc.. are discussed. Also addressed are investigations of printable optically/magnetically active nanocomposite and polymeric materials for fabrication of devices such as inductors, embedded lasers, and optical interconnects.

A thin film printable technology was developed to manufacture large‐area microelectronics with embedded passives, Z‐interconnects and optical waveguides, etc. The overall approach lends itself to package miniaturization because multiple materials and devices can be printed in the same layer to increase functionality.

The paper describes a new electro‐optical board technology, based on the discrete wiring principle. Isolated copper wires are embedded in the circuit board to realise the electrical interconnections. Glass optical fibres are embedded to obtain optical interconnections. The technology allows for crossovers and for electrical and optical interconnections on one layer of interconnection. As the technology can be applied on the level of package or multichip module, circuit board and backpanel, it has the ability to offer a complete solution for chip to chip electrical and optical interconnections. The paper will describe the basic manufacturing technology of the boards. The benefits of the technology from a system designer's viewpoint will be addressed. The problem of coupling light in and out of the embedded optical fibres will be discussed and the realisation of a first on‐board optical link via embedded optical fibres will be described.

The purpose of this paper is to provide an overview of the research in a project aimed at developing manufacturing techniques for integrated optical and electronic interconnect printed circuit boards (OPCB) including the motivation for this research, the progress, the achievements and the interactions between the partners.

Several polymer waveguide fabrication methods were developed including direct laser write, laser ablation and inkjet printing. Polymer formulations were developed to suit the fabrication methods. Computer‐aided design (CAD) tools were developed and waveguide layout design rules were established. The CAD tools were used to lay out a complex backplane interconnect pattern to meet practical demanding specifications for use in a system demonstrator.

Novel polymer formulations for polyacrylate enable faster writing times for laser direct write fabrication. Control of the fabrication parameters enables inkjet printing of polysiloxane waveguides. Several different laser systems can be used to form waveguide structures by ablation. Establishment of waveguide layout design rules from experimental measurements and modelling enables successful first time layout of complex interconnection patterns.

The complexity and length of the waveguides in a complex backplane interconnect, beyond that achieved in this paper, is limited by the bend loss and by the propagation loss partially caused by waveguide sidewall roughness, so further research in these areas would be beneficial to give a wider range of applicability.

The paper gives an overview of advances in polymer formulation, fabrication methods and CAD tools, for manufacturing of complex hybrid‐integrated OPCBs.

To introduce the Innovative Electronics Manufacturing Research Centre Flagship Project: Integrated Optical and Electronic Interconnect PCB Manufacturing, its objectives, its consortium of three universities and ten companies and to describe the university research being carried out. This paper briefly reviews the motivation for developing novel polymer formulations, fabrication techniques, layout design rules and characterisation techniques for hybrid electronic and optical printed circuit boards (PCBs) using multimode polymer optical waveguide interconnects.

The authors are investigating a number of different fabrication techniques which they compare with each other and with modelled calculations of waveguide components. The fabrication techniques include photolithography, laser ablation, direct laser writing, embossing, extrusion and ink jet printing.

A number of design rules for polymer multimode waveguides have been found and published. Techniques for ink jetting polymer to print waveguides and laser ablation techniques have been developed. New formulations of polymer which cure faster for direct writing have also been developed.

Further work is needed to thicken the ink jet printed polymer and to investigate side wall roughness of the ablated waveguides and development of new polymer formulations for dry film. Further research is also needed on construction of prototype system demonstrators.

The fabrication techniques being developed are designed to be transferred to industrial PCB manufacturers to enable them to make higher value optical PCBs. The design rules being discovered are being entered into commercial PCB layout software to aid designers of optical PCBs.

The paper is of interest to PCB manufacturers who wish to upgrade their processes to be able to manufacture optical PCBs. The university research is original and some has been published as shown in the publications in the reference list.

The purpose of this paper is to present the latest results from research and development into future optical printed circuit board (OPCB) interconnects and low‐cost assembly methods.

A novel method of high‐precision passive alignment and assembly to OPCBs was invented and a full evaluation platform developed to demonstrate the viability of this technique.

The technique was successfully deployed to passively align and assemble a lens receptacle onto an embedded polymer waveguide array in an electro‐OPCB. The lens receptacle formed a critical part of a dual lens pluggable in‐plane connection interface between peripheral optical devices and an OPCB. A lateral in‐plane mechanical accuracy of ±2 μm has been measured using this technique.

As this is a free space optical coupling process, surface scattering at the exposed waveguide end facet was significant.

This paper details a novel method of passively assembling arbitrary optical devices onto multi‐mode optical waveguides and outlines the procedure and equipment required. A lens coupling solution is also presented which reduces susceptibility of a connecting optical interface to contamination.

To present work and characterisation results from a project to develop a pluggable optical connector for board to board interconnect.

An optical backplane connection system is described, which allows for repeatable docking and undocking of an active optical interface housed on a daughtercard to waveguides fabricated on an optical backplane.

The optical backplane connection system described has demonstrated its successful implementation with respect to optical data transfer across multimode polymer waveguides. Measurement results presented show that such a system is a viable approach toward the application of pluggable optical backplane interconnects.

The direct connection to the exposed waveguide interface results in considerable optical loss and scattering. Future designs will have to address this. Additional work should also be undertaken to develop a means of connector engagement that is autonomous and requires no user intervention.

Prior research into the problem of coupling to an optical backplane has been concerned with interfaces that deflect optical signals by 90° into and out of the waveguides. Here, an alternative approach is proposed that launches light directly into the waveguide ends.