Optical Polymer Waveguides: From the Design to the Final 3D-Opto Mechatronic Integrated Device

Preface
Contents
1 Current Development in the Field of Optical Short-Range Interconnects
	1.1	Advantages of Optical Communication
	1.2	3D-Opto-MID for Optical Bus Systems
		1.2.1	Short-range optical waveguides networks
		1.2.2	Optical bus systems
		1.2.3	Current development in the field of 3D-Opto-MID
	1.3	New Approach for Additive Manufactured 3D-Opto-MID
	References
2 Computer-Aided Design of Electro-Optical Assemblies
	Abstract
	2.1	Demand on Software-Based Design Tools for Spatial Optoelectronics
	2.2	State of the Art in the Design of Electro-optical Circuits and MID
		2.2.1	General Procedures for Electronic and Electro-optical Assemblies
		2.2.2	Electronics Design Process
		2.2.3	Procedure for Spatial Electronic Assemblies (3D-MID)
		2.2.4	Procedure in electro-optical design
		2.2.5	Evaluation
	2.3	Need for Action for the Computer-aided Modeling of 3D-Opto-MID
		2.3.1	General Functional Requirements for a 3D Optomechatronic CAD System
		2.3.2	General Aspects
			2.3.2.1 Aspects of Design
			2.3.2.2 Aspects Resulting from Manufacturing
			2.3.2.3 Aspects of Software Systems
		2.3.3	Summary
	2.4	Concept of a Cross-domain Methodology for Optomechatronic Components
		2.4.1	Considerations for the Design and Workflow of a Computer-aided 3D-Opto-MID System
		2.4.2	Integration of Optical Functionalities in a 3D-OMCAD System
	2.5	Prototypical Integration of Optomechatronic Functions into a 3D-Opto-MID Design System
		2.5.1	Circuit Carrier and Substrate Modeling
		2.5.2	Synthesis of Circuits
		2.5.3	Waveguide Modeling, Routing Optimization and Wiring
			2.5.3.1 Manual Routing
			2.5.3.2 Automatic Routing
		2.5.4	Design Rule Checks
		2.5.5	Interface to Optical Simulation
	References
3 Three-Dimensional Simulations of Optical Multimode Waveguides
	3.1	Demands on the Simulation
	3.2	Geometric Optical Simulation
		3.2.1	State of the art for Raytracing
		3.2.2	Mathematical Properties for the Description of a POW
		3.2.3	Algorithm for Arbitrary Cross sections
		3.2.4	Impact of Manufacturing Parameters on the Optical Properties
	3.3	Physical Optical Simulation
		3.3.1	State of the art for Wave Propagation Method (WPM)
		3.3.2	Impact of Periodicity of Discrete Fourier Transform
		3.3.3	Simulation of Waveguides
	References
4 Conditioning of Flexible Substrates for the Application of Optical Waveguides
	4.1	Wetting Control by Conditioning
		4.1.1	Wetting and Capillarity
		4.1.2	Wetting Control by Changing the Chemical Properties
	4.2	State of the art for Functional Flexographic Printing
		4.2.1	Applications
		4.2.2	Flexographic Printing Process
	4.3	Selection and Design of the Printing Form
	4.4	Characterization and Selection of the Materials
		4.4.1	Selection of the Printing Varnish
		4.4.2	Selection of the Substrate Material
	4.5	Experimental Studies of the Conditioning Line Printing Process
		4.5.1	Experimental Setup
		4.5.2	Automated Evaluation of Geometric Quality
		4.5.3	Geometry of the Conditioning Lines
		4.5.4	Formation of Edge Ripples and Topography
	4.6	Modeling of Stamp Deformation in the Printing Process
	4.7	Manufacturing Three-Dimensional Optical Interconnects
		4.7.1	Studies on the Thermoforming of Conditioned Film Substrates
	4.8	Surface Functionalization for Wetting Behavior Adjustment of Flexographic Printing Forms
		4.8.1	Functionalization by Laser-Induced Microstructures
		4.8.2	Functionalization by Coating Mechanisms
		4.8.3	Functionalization by Chemical Modification
		4.8.4	Application of Functionalization Mechanisms on Flexographic Printing Forms and its Impact on the Printing Results
		4.8.5	Impact of the Functionalization on the Printing Results
	References
5 Aerosol Jet Printing of Polymer Optical Waveguides
	5.1	State-of-the-Art Fabrication of the Polymer Optical Waveguide
		5.1.1	Photolithography
		5.1.2	Photolysis
		5.1.3	Photolocking
		5.1.4	Photobleaching
		5.1.5	Reactive Ion Etching (RIE)
		5.1.6	Laser Ablation
		5.1.7	Dispense Printing
		5.1.8	Mosquito Method
		5.1.9	Inkjet Printing
		5.1.10	Aerosol Jet Printing
	5.2	Polymer Optical Waveguides Fabrication Through Aerosol Jet Printing
		5.2.1	Principles of Aerosol Jet Printing
		5.2.2	Selection of Polymer Optical Material for Aerosol Jet Printing Process
		5.2.3	Effect of the Material Temperature on the Mass Flow Output
	5.3	Fabrication Process Steps
		5.3.1	Motion3D: CADCAM Design and NC Code Generation
		5.3.2	Remote-NC: 5-Axes Kinematic System
		5.3.3	AJP Process Parameter
	5.4	Theoretical AJ Printed Polymer Optical Waveguide Geometry
	5.5	Strategies in Aerosol Jet Printed Polymer Optical Waveguide
		5.5.1	Single-layer Printing: Immediate UV Curing Process
		5.5.2	Multi-layer Printing: Immediate UV Curing Process
		5.5.3	Multi-layer Printing: UV Curing After the Complete Layer Printing
	5.6	Qualification and Characterization of the Printed Polymer Optical Waveguide
		5.6.1	Geometrical Properties
		5.6.2	Profile Dimension
		5.6.3	Effect of the Surface Roughness and Waviness
	5.7	Morphology Analysis
		5.7.1	Overspray
		5.7.2	Waviness
		5.7.3	Impurities
		5.7.4	Bulging
		5.7.5	Bubble or Air Pocket
	5.8	Mechanical and Optical Properties of the Printed Polymer Optical Waveguide
		5.8.1	Hot-Pin-Pull Test
		5.8.2	Shear Force Test
		5.8.3	Lifetime Performance Test
		5.8.4	Optical Quality
	5.9	Modeling and Simulation Analysis of the Aerosol Jet Printhead
		5.9.1	Modeling and Operational Principles
		5.9.2	Simulation Results Analysis
	5.10	Summary
	References
6 3D-Opto-MID Coupling Concept Using Printed Waveguides
	6.1	Coupling Strategies for Large-Scale Optical Networks
		6.1.1	Demands for Optical Bus Coupling
		6.1.2	State of the Art for Optical Bus Couplers
		6.1.3	Theoretical Basis for the Asymmetric Optical Bus Coupler
	6.2	Simulation of the Asymmetric Optical Bus Coupler
		6.2.1	Parameters for the Mathematical Model of the Bus Coupler
		6.2.2	2D Simulation
		6.2.3	3D Parameter Extension
		6.2.4	3D Simulation
	6.3	Performance of the Asymmetric Optical Bus Coupler
		6.3.1	Measurement Setup
		6.3.2	Coupling Results
		6.3.3	Data Transmission via the Asymmetric Optical Bus Coupler
		6.3.4	Long-Term Stability of the AOBC
	6.4	Technologies for Three-Dimensional Electro-Optical Interconnects
		6.4.1	Packaging Demands and State-Of-The-Art for 3D-Opto-MID
		6.4.2	Polymer–Ceramic Hybrid Assembly for 3D-Opto-MID
		6.4.3	Long-Term Stability of the 3D-Opto-MID
	References
7 Feasibility of Printed Optical Waveguides Over the Entire Process Chain by OPTAVER