Manufacturing system using solder self-alignment with optical component deformation fine alignment

Abstract

A process for assembling micro-optical systems, such as optoelectronic and/or fiber optic components uses solder self-alignment to achieve a coarse, passive alignment of optical components relative to the optical bench. The fine, final alignment is performed using plastic deformation of the optical components to thereby improve the alignment of the optical components. As a result, the sub-micrometer alignment accuracies are attainable, if required.

What is claimed is:  
     
         1 . An unpopulated optical bench precursor structure comprising: 
 a bench;    solder pads deposited on the bench at locations determined by engagement points between optical components and the optical bench; and    spacers on the bench and in or near the solder pads for supporting the optical components at a predetermined position vertically on the bench.    
     
     
         2 . An unpopulated optical bench precursor structure as claimed in  claim 1 , further comprising a template for facilitating the placement of optical components on the bench.