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OIDA Photonic Integration Forum

fibresystems.org is delighted to welcome Jeff Ferry, Director of Communications for Infinera, and a former journalist, as a guest blogger this week. Jeff will be reporting on the OIDA’s Photonic Integration Forum, which is the first industry conference dedicated to the commercial development of photonic integration technology. As such it marks an important step forward for this technology area. The conference has been co-organised by OIDA and Infinera.

The conference attracted an impressive 60 experts in photonic integration, says Jeff, filling the room to capacity at the picturesque Monterey Hotel and Spa, perched up against, and partially built out over, Monterey Bay, 100 miles south of San Francisco. So without further ado, over to Jeff…

Tuesday, 7 October, OIDA Photonic Integration Forum, Day One
By Jeff Ferry

Photonic integration
Photonic integration

The two most interesting themes of the conference’s first day were scalability and power consumption. The debate over scalability turned into a discussion of integration on indium phosphide vs. integration on silicon. The indium phosphide (InP) supporters, led by Infinera, have the benefit of having large numbers of photonic integrated circuits deployed by real customers. According to the chart shown by Infinera co-founder Dave Welch, Infinera has accumulated 101 million hours of PICs running in live networks without a single failure, with each PIC pair integrating 60 devices. That translates to a FIT rate (reliability measure) of 9, which is better than many single lasers and modulators in the market today. “Everything gets better when you integrate, reliability, yield, performance, and costs,” said Welch.

Later in the day, Infinera PIC engineer Randy Salvatore provided some insight into how Infinera has achieved its reliability and yields, describing the six stage statistical process control methodology that Infinera borrowed from the silicon industry and applied at its PIC fab. According to Salvatore, when compared to silicon chips and specifically Intel’s well-documented history, Infinera has in the last two years made progress equivalent to six years’ worth of Intel progress, moving from defect density numbers equivalent to Intel’s in 1987 to numbers comparable to Intel in 1993. This, said Salvatore, is the silicon learning curve successfully applied to InP.

Professor John Bowers of University of California at Santa Barbara emerged as the most charismatic advocate of silicon photonics. He showed slides on his UCSB team’s progress in several areas, including high-quality photodetectors made from silicon germanium, hybrid lasers made from a combination of III-V materials and silicon, and on the manufacturing side, they’ve reduced the time required to bond the two materials together from 12 hours to as low as 10 minutes — an important step towards making the technology practical, reliable, and commercial. Bowers said that silicon CMOS technology makes it possible to reduce device size to the point where it becomes possible to get as many as 125,000 die sites (i.e. chips) on an 8 inch wafer. All those developments go towards making silicon photonics PICs more cost-effective than any other material, said Bowers. “Infinera is doing a great job, but the potential for lots more scaling exists,” Bowers said. “The platform for VLSI PICs exists. Millions of devices [on a chip] is possible.”


The next speaker, Meint Smit, of the Technical University of Eindhoven, brought a touch of Dutch pessimism to the conference. He said that neither InP PICs nor silicon PICs could get beyond 1000 devices on a chip before the power consumption of the lasers would make the devices impractical. He presented an alternative, based on "digital nanophotonics," two tiny "microlasers" working in tandem to generate a single lightstream with far less power dissipation. He has labeled this technology "indium phosphide membrane on silicon" or IMOS, and said it allows for a much larger number of lasers per chip. His prediction was that IMOS technology could push PIC complexity to 100,000 devices on a chip.

Both IBM's Clint Schow and Sun Microsystems' Ashok Krishnamoorthy focused on the same problem: the growing power consumption of high-performance microprocessors in today's multithreaded, multicore computer servers. According to Schow, IBM's Cell processor (developed in partnership with Sony and used in Sony videogame controllers) consumes 100 W of power, with 30% of that total going to moving data either on and off the chip, or between the cores, buffers, and memory on the chip. Krishnamoorthy said that the growing power of servers in the data center has created a situation where power consumption has reached levels of 10 kW per square foot. Adding more threads and more cores simply adds to the need to move data around the processor chip or between chips, adding further to power consumption. "This is not sustainable. We are in a vicious thermal cycle," he said.

Both men said substituting optical interconnects for copper can make a big contribution to reducing power consumption. Krishnamoorthy said Sun has built a chip with 256 VCSEL lasers, each one operating at 1.25 Gbit/s and consuming just 12 W. Cost is also critical, so an optical interconnect needs to be able to move 1 Gbit/s of data 100 meters for a cost of around $2.

Schow presented an equally ambitious vision, not just optical interconnects based on PICs, but an "optical printed circuit board," based on polymer waveguides, onto which PICs and other optics devices can be placed on a volume production line just the way electronic boards are built today. He said IBM has demonstrated transceiver chips with 16 lasers and a data rate of 160 Gbit/s, based on hybrid technology. He said III-V materials are needed for the optical reach, and better manufacturing techniques need to develop, including better packaging techniques to align arrays of fiber to arrays of lasers. "Integration is key, and we need the right mix of hybrid, and monolithic," Schow said.

Eli Yablonovitch of UC Berkeley, and an adviser to California start-up Luxtera, described Luxtera's first product, the Blazar fiber optic cable, and showed that this company is very focused on cost. Blazar looks something like a USB cable, but inside the connector at each end of the cable is an optoelectronic transceiver based on silicon photonics technology that converts 4 x 10 Gbit/s of data from electronics to optics and back again. It has low power consumption and cost approaching that of copper. To develop this product, which is scheduled to begin volume shipments this quarter, Luxtera made significant innovations in grating couplers and developed a high-yield, high-volume manufacturing process. Applications are initially in high performance computing, but according to one conference attendee, the optical cable also has consumer electronics applications. If you need to get that HDTV signal from the cable box out to the backyard, this could be your answer.

NOTE: The views in this blog are the author's own and do not represent those of Infinera or any other organization.

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