The making of integrated optics
A US initiative is bringing together leading companies with top academics and universities to create a manufacturing infrastructure for the widespread adoption of integrated photonics.
The US sees integrated photonics as a strategic technology and has set up the American Institute for Manufacturing Integrated Photonics - AIM Photonics - to advance the technology and make it available to a wider community of companies. AIM Photonics, with $610 million of public and private funding, is a five-year initiative ending in 2020. AIM’s long-term goal is to be self-sustaining.
Doug Coolbaugh
“Right now the infrastructure is focussed on electronics and CMOS but photonics is going to be the future,” says Doug Coolbaugh, chief operations officer at AIM Photonics. “There is no other way to do it [very high bandwidth] except using light for ultra fast communications.”
Technologies start at universities and in the labs of companies with large R&D budgets. IBM and Intel, for example, have been developing silicon photonics for over a decade and the technology is ready for deployment. However, the intellectual property developed remains with such companies.
“AIM is not only creating the manufacturing infrastructure for integrated photonics but also ideas and intellectual property that can be used by companies for new products,” says Coolbaugh.
All the elements are being addressed so that small to medium businesses and entrepreneurial ventures can use integrated photonics for their products; companies too small to develop the technology themselves. “That will accelerate the silicon photonics ecosystem and allow new products to come out much faster than it would normally take,” says Coolbaugh.
Manufacturing
Silicon photonics luminary, Lionel Kimerling, professor of materials science and engineering at MIT, and an active member of AIM Photonics, views its focus on manufacturing as an important development.
The discipline of manufacturing is something that the chip industry has mastered through designing process integration, selecting materials and all the qualification standards used to meet system requirements, he says, but is less developed in the photonics industry.
AIM is making available a chip fabrication plant to interested companies. SUNY Polytechnic Institute has been working with MIT for the last six years to develop a 300mm-wafer silicon photonics line at its Albany site. The fab offers a multi-project wafer service whereby several designs can be made on a single wafer, allowing costs to be shared among companies.
AIM is not only creating the manufacturing infrastructure for integrated photonics but also ideas and intellectual property that can be used by companies for new products
A design kit is also being developed featuring key building blocks needed to make an integrated photonics circuit. AIM is working with leading semiconductor industry design automation companies Cadence, Synopsys and Mentor Graphics to provide the software tool environment for designers to develop circuits. “This design environment is compatible with the silicon photonics process here in our fab,” says Coolbaugh.
A packaging and prototyping facility located in Rochester, New York is also being set up. “Photonics packaging is relatively new and certain aspects have not been developed that much,” says Coolbaugh.
Another issue is developing skilled engineers and technicians able to design and manufacture integrated photonics circuits. Whereas electronic chip designers typically have a first degree, photonics engineers tend to have a doctorate because of the deep understanding needed. “This is one of the things we find we are lacking significantly,” says Coolbaugh. “There are just not enough skilled people in the industry to fulfil these needs.”
Professor Kimerling says he is spending much of his time putting together educational material to help attract individuals to pursue a career in silicon photonics. Much of the technology is in place, he says, what is required is to make it accessible to people. “I don’t have 40 more years in the industry, but I could influence the next 40 years by creating these instructional materials and career paths, and getting roadmap consensus that can drive the industry,” says Kimerling.
AIM is also working with universities and companies to develop technology and intellectual property alongside the manufacturing centres. Four research areas have been chosen, covering datacom, analogue RF for telecom involving Infinera, sensors and phased arrays. These are areas where AIM sees products emerging in volume in the next five years.
Keren Bergman, whose work focusses on the intersection of photonics and computing systems, mentions how AIM Photonics has already benefited her research group through much closer interactions with companies in the area of datacom. “It has had a big impact on our work,” says Bergman, professor and director at the Lightwave Research Laboratory at Columbia University.
Each year AIM will review and add new research topics. “There are new ideas, new materials and new manufacturing processes that will be developed,” says Coolbaugh. He cites the use of silicon photonics to drive robots as an emerging application area.
Status
AIM expects the entire manufacturing infrastructure to be in place in the next couple of years.
“Right now it is only the photonics design part but we will also be putting in interposers for packaged designs," says Coolbaugh. Interposers are a key technology that allows the co-packaging of chip dice, an approach known as system-in-package or 2.5D packaging.
AIM expects to offer multi-project wafers with interposers and system-in-package by 2017, with the ability to add CMOS dice in 2018. AIM is also developing a test, assembly and packaging facility which it expects to be available by 2018. “Testing is a really critical component of this entire infrastructure,” says Coolbaugh.
The goal is to develop new ways of fast-testing photonics on wafers, while there will be the high-speed testing of circuits at Rochester. “What we design has got to work in the fab, the fab has got to test well and then what we package has to be consistent with what we deliver to the packaging house,” says Coolbaugh. “The entire flow has to integrate exactly.”
A start-up or small company wanting to make a product can already use the design kit - which continues to evolve - and benefit from AIM’s multi-project wafer service. Then there will be the Rochester packaging and prototyping site. Low volumes can be made at the Albany fab while AIM will pass higher-volume manufacturing requests to leading chip fabrication players such as GlobalFoundries.
Companies can take a concept, develop their own product and have their own business. “We provide the entire chain for the infrastructure,“ says Coolbaugh. ”Right now, this is only available to large companies.”
If all goes to plan, what impact will AIM have on integrated optics and silicon photonics in particular? “It will be a worldwide impact,” says Coolbaugh. “Just because we want to create the infrastructure in the US doesn’t mean we are limiting our customers to the US.”
Further information
For AIM Photonics presentations, click here
The text is based on an article that first appeared in Optical Connections magazine
Juniper Networks to acquire Aurrion for $165 million
The announcement of the acquisition was low key. A CTO blog post and a statement that Juniper Networks had entered into an agreement to acquire Aurrion, the fabless silicon photonics start-up. No fee was mentioned.
However, in the company's US Securities and Exchange Commission filing, Juniper values the deal at approximately $165 million. "The Company believes the acquisition will help to fuel its long-term competitive advantage by enabling cost-effective, high-density, high-speed optical networks," it said. The deal is expected to be closed this quarter.
But the deal is significant for a number of reasons.
First, Aurrion, like Intel, is a proponent of heterogeneous integration, combining indium phosphide and other technologies on a silicon wafer platform through bonding. The approach has still to be proven in commercial volumes but it promises the use of III-V materials on 12-inch silicon wafers manufactured in a chip fabrication plant.
Aurrion has made tunable lasers for telecom that cover both the C- and L-bands, as well as uncooled laser arrays for datacom applications. The start-up has also been developing high-speed transceivers for the data centre.
The company has also been working on the manufacturing aspects of silicon photonics, a considerable undertaking. These include automated wafer-scale testing, connecting fibre to a silicon photonics chip, and packaging.
Juniper is thus getting an advanced silicon photonics technology suited for volume manufacturing that it will use to advance its data centre networking offerings.
Juniper may choose to make its own optical transceivers but, more likely, it will use silicon photonics as part of its switch designs to tackle issues of data centre scaling and the continual challenge of growing power consumption. It could also use the technology for its IP core routers and longer term, to tackle I/O issues alongside custom ASICs.
Systems vendors drive silicon photonics
The Aurrion acquisition also highlights how it is systems vendors that are acquiring silicon photonics start-ups rather than the traditional optical component and module makers.
This is partly a recognition that silicon photonics' main promise is as a systems technology. Acacia, the coherent transmission specialist, is one company that has shown how silicon photonics can benefit optical module design but the technology's longer-term promise is for systems design rather than optical modules.
A consequence of such acquisitions by systems vendors is that technology being developed by silicon-photonics start-ups is being swallowed within systems houses for their own use and not for the merchant market. Systems vendors have deep pockets to develop the technology but it will be for their own use. For the wider community, silicon photonics technology being developed by the likes of Aurrion is no longer available.
This is what AIM Photonics, the US public-private partnership that is developing technology for integrated photonics, is looking to address: to advance the manufacturing of silicon photonics, making the resulting technology available to small to medium sized businesses and entrepreneurial ventures. However, AIM Photonics is one year into a five-year venture.
Implications
Should major systems vendors owning silicon photonics technology in-house concern the traditional optical component vendors?
Not for now.
Optical transceiver sales continue to grow and the bulk of designs are not integrated. And while silicon photonics is starting to be used for integrated designs, it is competing against the established technologies of indium phosphide and gallium arsenide.
But as photonics moves closer to the silicon and away from a system's faceplate, silicon photonics becomes more strategically important and this is where systems vendors can start developing custom designs.
Must the systems houses own the technology to do that?
Not necessarily, but they will need silicon photonics design expertise, and in the case of Juniper, it can hit the ground running with Aurrion.
Longer term, it will be the much larger chip industry that will drive silicon photonics rather than the optical industry. There are chip foundries now that are making silicon photonic ICs as there are top-ten chip companies such as Intel and STMicroelectronics. But ultimately it will be a very different supply chain that will take shape.
It is early days but Juniper's acquisition is the latest indicator that it is the systems vendors that are moving first at the very beginnings of this new ecosystem.
Richard Soref: The new frontiers of silicon photonics
Interview 4: Professor Richard Soref
John Bowers acknowledges him with ‘kicking off’ silicon photonics some 30 years ago, while Andrew Rickman refers to him as the ‘founding father of silicon photonics’. An interview with Richard Soref.
It was fibre-optic communications that started Professor Richard Soref on the path to silicon photonics.
“In 1985, the only photonic chip that could interface to fibre was the III-V semiconductor chip,” says Soref. He wondered if an elemental chip such as silicon could be used, and whether it might even do a better job. He had read in a textbook that silicon is relatively transparent at the 1.30-micron and 1.55-micron wavelengths used for telecom and it inspired him to look at silicon as a material for optical waveguides.
Soref's interest in silicon was a combination of the potential of using the chip industry’s advanced manufacturing infrastructure for electro-optical integration and his own interest in materials. “I’m a science guy and I have curiosity and fascination with what the world of materials offers,” he says. “If I have an avenue like that, I like to explore where the physics takes us.”
In 1985 Soref constructed and did experiments on waveguides based on un-doped silicon resting upon a doped silicon substrate. It turned out not to be the best choice for a waveguide and in 1986 Soref proposed using a silicon-on-insulator waveguide instead, what has become the mainstream approach for the silicon photonics industry.
Silicon-on-insulator had a far greater refractive index contrast between the waveguide core and its cladding and is far less lossy. And while Soref didn’t build such structures, “it stimulated others to develop that major, major waveguide, so I’m proud of that”.
The original waveguide idea was not a wasted one, though. Soref and then research assistant, Brian Bennett, used the undoped-on-doped silicon waveguide structure to study and quantify free-carrier electro-modulation effects. These effects underpin the workings of the bulk of current silicon photonic modulators. Soref says their published academic paper has since been cited over 1,800 times.
Soref is approaching his 80th birthday and is a research professor at the University of Massachusetts in Boston. He has spent over 50 years researching photonics, silicon photonics and the broader topic of mid-infrared wavelengths and Group IV photonics, as well as spending five years researching liquid crystals for displays and electro-optical switching. For 27 years he was employed at the Air Force Research Laboratory. He has also worked at the Sperry Research Center and the MIT Lincoln Laboratory.
Applications go beyond telecom and optical interconnect, and perhaps the most important application is sensing
Group IV photonics
Soref’s research interests are broad as part of his fundamental interest in material science. In more recent years he has focused on Group IV photonics but not exclusively so.
The term silicon-photonics is firmly entrenched in the global community, he says, a phrase that includes on-chip germanium photo-detectors and even, with heterogeneous integration, III-V materials. Group IV photonics is a superset of silicon photonics and includes silicon-germanium-tin materials (SiGeSn) and well as silicon carbide. Such materials will likely be used in the monolithic silicon chip of the future, he says.
He has published papers on alloys such as silicon germanium carbon and silicon germanium tin. “I was estimating what these never-before-seen materials would do; you could create new alloys and how would those alloys behave,” says Soref.
Silicon germanium tin offers the possibility of a direct bandgap light emitter. “It is a richer material science space, with independent control of the bandgap and the lattice parameter,” says Soref.
Adding tin to the alloy lengthens the wavelength of operation, typically in the 1.5-micron to 5-micron range, the near infra-red and part of the mid infra-red part of the spectrum. “Applications go beyond telecom and optical interconnect, and perhaps the most important application is sensing,” says Soref.
The applications in this wavelength range include system-on-a-chip, lab-on-a-chip, sensor-on-a-chip and sensor-fusion-on-a-chip for such applications as chemical, biological, medical and environmental sensing. Such sensor chips could be in your smartphone and play an important role in the emerging Internet of Things (IoT). “Sensing could be a very important economic foundation for Group IV photonics,” says Soref.
And Soref does not stop there. He is writing a paper on Group III nitrides for ultra violet and visible-light integrated photonics: “I think silicon and Group IV are limited to the near-, mid- and longwave infra red”.
Challenges
Soref points to the work being done in developing commercial high-volume manufacturing: the use of 300mm silicon wafers, developing process libraries and perfecting devices for volume manufacturing. He welcomes AIM Photonics, the US public-private venture investing $610 million in photonics and manufacturing.
But he argues that there should also be an intellectual space for growth, “a wider space which is not so practical but which will become practical”. He cites the emerging areas of sensing and microwave photonics. “That is the frontier,” says Soref. “And the foundry work should not prevent that intellectual exploration.”
An important application area for microwave photonics is wireless, from 5GHz to 90GHz. Soref envisages a photonic integrated circuit (PIC), or an opto-electronic IC (OEIC) that features electronics and optics on-chip, that communicates with other entities often via fibre but also wirelessly.
“That means RF (radio frequency) or microwave, and for microwave that requires a transmitter and receiver on the chip,” says Soref. Such a device would find use in the IoT and future smartphones.
Microwave designs in the past used an assemblage of discrete components that makes a system on a board. These new microwave PICs or OEICs could perform many of the classical functions such as spectral analysis, optical control of a phased array microwave antenna, microwave signal processing, and optical analogue to digital conversion (ADC) and optical digital to analogue conversion (DAC).
This is analogous to the convergence of computing and photonics, says Soref. In computing, the signal goes from the electrical domain to the optical and back, while for microwave photonics it will be conversions between the microwave and photonic domains on the chip.
There are also quantum-photonic applications: quantum computing, quantum cryptography and quantum metrology where photonic devices could play a role.
Opportunities
These are the three emerging opportunities areas Soref foresees for Group IV photonics emerging in the next decade: sensors, microwave photonics and the quantum and computing worlds in addition to the existing markets of telecom and optical interconnect.
Soref is not sure that silicon photonics has yet reached its tipping point. “To make silicon photonics and Group IV photonics ubiquitous and pervasive, it takes a lot of investment and a lot of commercial results,” he says. “We have not yet arrived at that stage of economic foundation.”
New optical devices
Soref also highlights how continual advances in CMOS feature size, from 45nm down to 7nm, promise new photonic components that could become commonplace.
Soref cites the example of a silicon-on-isolator nanobeam. The nanobeam is a strip waveguide with air holes, in effect a one-dimensional photonic crystal lattice in a waveguide.
The nanobeam structure is of interest as it performs the same role as the micro-ring resonator, a useful optical building block used in such applications as modulation.
“The photonic crystal structure requires extreme control of dimensions to reduce unwanted scattering, so it needs very fine lithography,” says Soref. People have argued such structures are impractical due to the unrealistic dimensional control needed.
“But foundries have shown you can get a very high-quality photonic crystal in a silicon fab,” he explains. “This foundry advantage would enable new components that might have seemed too difficult or marginal on paper.”
Significant progress in silicon photonics may have been achieved since his first work in 1985, but as Soref highlights, it is still early when assessing the full significance of the technology.
Mario Paniccia: We are just at the beginning
During that time, his Intel team had six silicon photonics papers published in the science journals, Nature and Nature Photonics, and held several world records - for the fastest modulator, first at 1 gigabit, then 10 gigabit and finally 40 gigabit, the first pulsed and continuous-wave Raman silicon laser, the first hybrid silicon laser working with The University of California, Santa Barbara, and the fastest silicon germanium photo-detector operating at 40 gigabit.It got to the stage where Intel’s press relations department would come and ask what the team would be announcing in the coming months. “ 'Hey guys,' I said, 'it doesn't work that way ' ”.
Since leaving Intel last year, Paniccia has been working as a consultant and strategic advisor. He is now exploring opportunities for silicon photonics but in segments other than telecom and datacom.
“I didn't want to go into developing transceivers for other big companies and compete with my team's decade-plus of development; I spent 20 years at Intel,” he says.
Decade of development
Intel’s silicon photonics work originated in the testing of its microprocessors using a technique known as laser voltage probing. Infra-red light is applied to the back side of the silicon to make real-time measurements of the chip’s switching transistors.
For Paniccia, it raised the question: if it is possible to read transistor switching using light, can communications between silicon devices also be done optically? And can it be done in parallel to the silicon rather than using the back side of silicon?
In early 2000 Intel started working with academic Graham Reed, then at the University of Surrey, and described by Paniccia as one of the world leaders in silicon photonics devices. “We started with simple waveguides and it just progressed from there,” he says.
The Intel team set the target of developing a silicon modulator working at 1 gigahertz (GHz); at the time, the fastest silicon modulator operated at 10 megahertz. “Sometimes leadership is about pushing things out and putting a stake in the ground,” he says.
It was Intel’s achievement of a working 1GHz silicon modulator that led to the first paper in Nature. And by the time the paper was published, Intel had the modulator working at 2GHz. The work then progressed to developing a 10 gigabit-per-second (Gbps) modulator and then broadened to include developing other silicon photonics building-block devices that would be needed alongside the modulator – the hybrid silicon laser, the photo-detector and other passive devices needed for an integrated transmitter.
There is a difference between proving the technology works and making a business out of it
Once 10Gbps was achieved, the next milestone was 20Gbps and then 40Gbps. Once the building block devices achieved operation in excess of 40Gbps, Intel’s work turned to using these optical building blocks in integrated designs. This was the focus of the work between 2010 to 2012. Intel chose to develop a four-channel 40Gbps (4x10 gigabit) transceiver using four-wavelength coarse WDM which ended up working at 50Gbps (4x12.5 gigabit) and then, most recently, a 100Gbps transceiver.
He says the same Intel team is no longer talking about 50Gbps or 100Gbps but how to get multiple terabits coming out of a chip.
Status
Paniccia points out that in little more than a decade, the industry has gone from not knowing whether silicon could be used to make basic optical functions such as modulators and photo-detectors, to getting them to work at speeds in excess of 40Gbps. “I’d argue that today the performance is close to what you can get in III-V [compound semiconductors],” he says.
He believes silicon photonics is the technology of the future, it is just a question of when and where it is going to be applied: “There is a difference between proving the technology works and making a business out of it”.
In his mind, these are the challenges facing the industry: proving silicon photonics can be a viable commercial technology and determining the right places to apply it.
For Paniccia, the 100-gigabit market is a key market for silicon photonics. “I do think that 100 gigabit is where the intercept starts, and then silicon photonics becomes more prevalent as you go to 200 gigabit, 400 gigabit and 1 terabit,” he says.
So has silicon photonics achieved its tipping point?
Paniccia defines the tipping point for silicon photonics as when people start believing the technology is viable and are willing to invest. He cites the American Institute for Manufacturing Integrated Photonics (AIM Photonics) venture, the $610 million public and private funded initiative set up in 2015 to advance silicon photonics-based manufacturing. Other examples include the silicon photonics prototyping service coordinated by nano-electronics research institute imec in Belgium, and global chip-maker STMicroelectronics becoming a silicon photonics player having developed a 12-inch wafer manufacturing line.
Instead of one autonomous LIDAR system in a car, you could have 20 or 50 or 100 sprinkled throughout your vehicle
“All these are places where people not only see silicon photonics as viable but are investing significant funds to commercialise the technology,” says Paniccia. “There are numerous companies now selling commercialised silicon photonics, so I think the tipping point has passed.”
Another indicator that the tipping point has happened, he argues, is that people are not spending their effort and their money solely on developing the technology but are using CMOS processes to develop integrated products.
“Now people can say, I can take this process and build integrated devices,” he says. “And when I put it next to a DSP, or an FPGA, or control electronics or a switching chip, I can do things that you couldn't do next to bulky electronics or bulky photonics.”
It is this combination of silicon photonics with electronics that promises greater computing power, performance and lower power consumption, he says, a view shared by another silicon photonics luminary, Rockley Photonics CEO, Andrew Rickman.
Moreover, the opportunities for integrated photonics are not confined to telecom and datacom. “Optical testing systems for spectroscopy today is a big table of stuff - lasers, detectors modulators and filters,” says Paniccia. Now all these functions can be integrated on a chip for such applications as gas sensing, and the integrated photonics device can then be coupled with a wireless chip for Internet of Things applications.
The story is similar with autonomous vehicle systems that use light detection and ranging (LIDAR) technology. “These systems are huge, complicated, have a high power consumption, and have lots of lasers that are spinning around,” he says. “Now you can integrate that on a chip with no moving parts, and instead of one autonomous LIDAR system in a car, you could have 20 or 50 or 100 sprinkled throughout your vehicle”
Disruptive technology
Paniccia is uncomfortable referring to silicon photonics as a disruptive technology. He believes disruption is a term that is used too often.
Silicon photonics is a technology that opens up a lot of new possibilities, he says, as well as a new cost structure and the ability to produce components in large volume. But it doesn’t solve every problem.
The focus of the optical vendors is very much on cost. For markets such as the large-scale data centre, it is all about achieving the required performance at the right cost for the right application. Packaging and testing still account for a significant part of the device's overall cost and that cannot be forgotten, he says.
Paniccia thus expects silicon photonics to co-exist with the established technologies of indium phosphide and VCSELs in the near term.
“It is all about practical decisions based on price, performance and good-enough solutions,” he says, adding that silicon photonics has the opportunity to be the mass market solution and change the way one thinks about where photonics can be applied.
“Remember we are just at the beginning and it will be very exciting to see what the future holds.”
US invests $610 million to spur integrated photonics
Prof. Duncan Moore
Dubbed the American Institute for Manufacturing Integrated Photonics (AIM Photonics), the venture has attracted 124 partners includes 20 universities and over 50 companies.
The manufacturing innovation institute will be based in Rochester, New York, and will be led by the Research Foundation for the State University of New York. A key goal is that the manufacturing institute will continue after the initiative is completed in early 2021.
We are at the point in photonics where we were in electronics when we still had transistors, resistors and capacitors. What we are trying to do now is the equivalent of the electronics IC
While the focus is on photonic integrated circuits, the expectation is that the venture will end up being broader. “NASA, the Department of Energy and the Department of Defense are all interested in using this as a vehicle for doing other work,” says Duncan Moore, professor of optics at the University of Rochester.
The venture will address such issues as design, on-chip manufacturing, packaging and assembly of PICs. “We are at the point in photonics where we were in electronics when we still had transistors, resistors and capacitors,” says Moore. “What we are trying to do now is the equivalent of the electronics IC.”
"It is an amazing public-private consortium utilizing an unprecedented $610 million investment in photonics," says Richard Soref, a silicon photonics pioneer and a Group IV photonics researcher. "The large and powerful team of world-class investigators is likely to make research-and-development progress of great importance for the US and the world.”
Project plans
The first six months are being used to fill in project’s details. “There are overall budget numbers but individual projects are not well defined in the proposal,” says Moore, adding that many of the subfields - packaging, sensors and the like - will be defined and request-for-proposals issued.
An executive committee will then determine which projects are funded and to what degree. Project durations will vary from one-offs to the full five years.
The large and powerful team of world-class investigators is likely to make research-and-development progress of great importance for the US and the world
Companies backing the project include indium phosphide specialist Infinera as well as silicon photonics players Acacia Communications, Aurrion, and Intel. How the two technologies as well as Group IV photonics will be accommodated as part of the manufacturing base is still to be determined, says Prof. Moore. His expectation is that all will be investigated before a ‘shakeout’ will occur as the venture progresses.
The focus will be on telecom wavelengths and the mid-wave 3 to 5 micron band. “There are a lot of applications in that [longer] wavelength band: remote sensing, environmental analysis, and for doing things on the battlefield,” says Moore.
A public document will be issued around the year-end describing the project’s organisation.
Further information:
The White House factsheet, click here
A Photonics video interview with the chairman of the institute, Professor Robert Clark, click here