SABIC Introduces EXTEM™ RH Resins for Micro-Lens Arrays

SABIC, a leader in the plastics and rubber industry, is set to launch its latest innovation, EXTEM™ RH resins. These high-performance resins are designed for use in the production and assembly of micro-lens arrays (MLAs), offering advanced scalability and manufacturability in commercial onboard and co-packaged optics.

"As data traffic increases exponentially, driven by AI, IoT and 5G technologies, rapid adoption of opto-electronics has become critical for improving data center bandwidth capacity and energy efficiency," said Scott Fisher, General Manager of Technology at SABIC Specialties.

EXTEM™ RH resins offer key performance benefits and processing capabilities for MLAs, addressing the challenges of traditional materials like glass and thermosets. These resins can be injection-molded into a wide variety of free-form optical lens designs, thanks to their high glass transition temperature of 280°C. This flexibility allows for the production of complex-shaped lens arrays without secondary operations like grinding and polishing, providing a more cost-effective solution.

To demonstrate their utility, SABIC's EXTEM™ RH resins have been used to create beam-expanding optical elements. These elements are installed on each side of the optical connector interface, coupling the fiber array to larger free-space beams. This approach relaxes lateral alignment tolerances and reduces occlusion from contamination, like dust particles.

High-volume production of micro-optics with a relatively low per-part cost is a significant challenge with traditional materials like fused silica or glass. In contrast, EXTEM™ RH resins support micro-molding, allowing for the efficient production of millimeter-sized components at scale while maintaining high signal integrity and low optical loss.

SABIC's unique approach also involves using optically transparent adhesives to align micro-optics with fiber and photonic integrated circuits (PICs) before the reflow step. This simplifies the packaging process, offering a streamlined solution for the manufacturing of optical components.

SABIC's approach to co-packaged optics goes beyond just introducing new materials. The company also demonstrates an alternative interconnect material, nano-silver sintering paste, developed collaboratively with the Chip Integration Technology Center (CITC). This paste can replace standard epoxy adhesives, providing better stability and reducing thermal expansion coefficient (CTE) mismatches.

Another feature of SABIC's technology is the ability to create lens arrays with total internal reflection. This innovation allows for a 90-degree bend of the optical coupling between VCSEL/PD and PIC in a standard MT ferrule connector, showcasing the flexibility of EXTEM™ RH resins.

The high-heat-resistant EXTEM™ RH resins recently won a 2023 Edison Award Gold Medal in the Next Generation Manufacturing category, underlining their impact on the industry. With SABIC's support from its Optical Center of Excellence in the Netherlands, customers can access advanced assistance in thermoplastic processing, component design, and optical performance measurement.