PILightning | Physik Instrumente (PI)

Solving the First Light Problem. With PILightning.

One of the critical challenges in scaling and the top cost driver for photonics device manufacturing are the precise alignment of optical components. By performing optimization in parallel across multiple channels, components, and degrees of freedom, Fast Multichannel Photonics Alignment (FMPA) reduces the time and costs for the manufacturing and testing of photonic devices and improves yield.

But before the optimization process can even start, an optical signal, above the noise level, must be detected—a process called first light detection. Finding first light has been a time-consuming procedure in all industrial photonics alignment applications, including wafer probing and device packaging, but it is particularly time-consuming in devices with inputs and outputs where both sides must be lined up for even a threshold amount of coupling to be achieved.

First Light Search Revolutionized

PILightning is based on a new search method with integrated AI-based real-time executive function. The fully automated and virtually instantaneous process eliminates the need for extensive calibration or manual intervention. With high frequency data sampling replacing fine pitch scanning, alignment speeds are raised significantly.

Once first light is detected, the FMPA fast gradient search algorithm takes over, utilizing real-time feedback control to swiftly optimize the alignment in parallel across the degrees-of-freedom and channels. Depending on the application, a tracking algorithm can be activated to maintain maximum coupling efficiency.

Single- and Double-Sided Alignment

Tests have shown improvements of one order of magnitude and more in single-sided alignment applications. Even higher gains are achieved in double-sided first light detection applications. The larger the search area and the more complex the alignment, the more significant the gain.

PI’s award-winning photonics alignment solutions:

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Availabilities for Existing Systems

The PILightning algorithm is immediately available on PI’s air bearing-based F-143 multi-axis photonics alignment system as well as ACS-based NanoCube and steering mirror controllers. Further modular expansion and potential upgrades to existing FMPA systems are being developed.

PI’s award-winning photonics alignment solutions:

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“The PILightning model is a quantum leap forward: It promises to improve alignment time by orders of magnitude.”

Our product marketing expert on air bearing products, Nikta Jalayer, gives insights into the thrilling development process of PI's photonics alignment solution, PILightning.

Implications for the Photonics Industry

Cost Savings: By drastically reducing alignment times, the technology enhances the efficiency of photonics manufacturing processes. This leads to reduced production times, lower costs, and increased competitiveness. The reduced need for skilled technicians allows for resources to be allocated more strategically.

Higher Throughput: Faster alignment equals higher throughput for manufacturers—this is particularly crucial in high-volume applications such as wafer probing and device packaging.

New Applications: The improvements in efficiency and reduction of costs open up possibilities for photonics applications in fields where precision alignment was previously a limiting factor.

Research Advancements: In research and development, the algorithm's speed allows for quicker testing and prototyping of optical components and systems, accelerating progress in photonics innovations.

Photonics

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Experience New Levels of Photonics Alignment.