Alignment and fabrication of micro-optic assemblies using fiber fusion

Considerable time for alignment is typically spent in the assembly of fiber optic components and subsystems. Presented here is a process that allows for pick-and-place assembly and automated alignment of these components. Fibers that are normally pre-attached to collimating or coupling lenses are left free in this process. The fiber position can then be re-located at the point of optimum performance by actively monitoring system performance. The fiber alignment can compensate for misalignment of the primary assembly components. Once the optimum fiber position is achieved the fiber is fused to the collimating or coupling lens element to provide the best mechanical and thermal stability of the finished assembly.