Polycision: Technological Issues

Steps to Successfully Packaging a Photonic or Optoelectronic Component

Paul Haugsjaa, Ph.D.
Polycision, Inc.
9/23/02

As a growing number of companies come to the realization that packaging and assembly operations are key to producing a cost- effective, reliable product; issues of design, intellectual property management, quality control and effective utilization of contract manufacturing resources must be addressed in a timely and cost effective way. The proven methods of packaging electronic components, while selectively applicable, are simply not sufficient for most photonic or optoelectronic components. Polycision and its principals have a wealth of experience ranging from optoelectronic packaging to IP analysis and development of sustainable funded research programs to meet the needs of high technology content products within the optics, electrochemistry, ceramics, fiber optic communications and power conversion fields.

A list of steps to be undertaken in implementing a successful packaging effort include the following:

1. Understand market forces - It is important to understand the needs of the target industry, what is acceptable, cost, materials, size, etc. If specifications or standards apply, these must be clearly understood and either adhered to closely or consciously ignored. Often intellectual property restrictions (or possibly opportunities) are in play in addressing any product opportunity and it is critical to understand how these can effect the long-term viability of the product and, ultimately, the company. Finally, the proper timing of development and product introduction are essential for success.

2. Understand the physics of the operation of the particular device to be packaged, its capabilities, its limitations, and how it will be expected to evolve in performance and form as products in the years to come.

3. Pull together the team - This sometimes means that it will be necessary to recruit the best possible people to help get the job done, making sure that the new team members will fit well with the existing members. At other times, it can mean training existing team members to provide for contributions in new areas. One shouldn't ignore the possibility that a seasoned team member with some coaching and consultation can fill your new requirements. Contract engineering and manufacturing services should always be considered as a means to augment team skills. In dealing with contract manufacturing organizations it is critical to establish in advance several points: 1. A method by which expectations for production quantities will be clearly defined 2. Mechanisms for changing these expectations 3. Expectations for the schedule of development and production, and 4. An agreed upon schedule for how costs are expected to scale with production volume. While there may be some concerns from an intellectual property (IP) perspective, most contract engineering and manufacturing organizations are well adapted to maintaining good IP separation between customers and the experience base derived from dealing with a contract engineering or manufacturing organization often provides distinct benefits in allowing timely product introductions, scaling of production and freedom from facilities development and maintenance issues. Whatever the make-up of the team, it will be necessary to plan how to maintain team efficiency and focus. The very nature of a package development team with its required diverse skill sets, makes these teams challenging to manage and motivate, but exciting to watch in action.

4. Set down the specifications for the final component - In as much detail as possible give the team (with their input, of course) the guidance they need to develop the engineering solutions to the packaging problem they have each been assigned. While it is best to keep these specifications as tight and fixed as possible, one should be open to changing them (making them tighter or relaxing them) as needs and opportunities arise. Along with the specifications for performance and reliability the team should agree on the timing of the development.

5. Plan the developmental program - There should be a schedule for development to be followed with major tasks and subtasks defined and assigned to specific individuals. The timing of starting and completing these tasks should be consistent with the overall project flow, leaving at least some room for the unexpected. It is crucial that members of the team sign up for the responsibility of completing their portion of the development and understand how they fit with completion of the overall plan.

6. Establish several trial designs - Trial designs should include (as closely as possible) elements of the final package and assembly method to be used.

7. Conduct modeling - This should include both thermal modeling and mechanical modeling utilizing finite element analysis, checking result validity by applying analytical methods and experienced based "rules". Modeling should be used to modify the trial designs to the point that team members are confident that the revised design can meet the specifications.

8. Conduct trial experiments - Using materials and geometries as near as possible to the eventual product (particularly in critical areas identified by the modeling) conduct experimentation involving trial assembly operations and testing under operating, storage, and shipping conditions. This will confirm that device operation will not be outside the specifications and that assembly operations are within the tolerance of the manufacturing environment selected including the time and precision required.

9. Review pertinent intellectual property (IP) restrictions and opportunities - Consider the IP that is utilized in the packaging operation and determine whether or not there might be issues of infringement that would require royalties or provide other encumbrances that must be eliminated. Additionally, consider the possibility of locking in the IP developed for the product by applying for patents, copyrights, etc. Throughout the development the team must be carefully instructed on how to recognize the need and lay the groundwork for skillfully implemented patent applications and possible future defense of patent validity and date of invention. A key to this task will be a careful assessment of IP by a third party to determine the nature, scope, and marketplace value of core IP developed and used in establishing this product. It is a critical point that merely patenting a company's own technology does not insulate one from infringing a competitors patent. If there is an infringement issue, it is best to recognize it up front. In a world where products and patents have international impact, it goes nearly without saying that a global perspective must be maintained on this issue.

10. Tune the timing of product completion and introduction for maximum market impact. Today this task is of critical importance as system developers await timing predictions for orders from the user community to finalize product offerings. This means that it is not enough to be first with the product offering, it is necessary to be competitive at the time when the product is being selected by a user (with the lowest cost, best performance, greatest reliability, etc). This places an added burden on component manufacturers to be sure products already introduced are simply upgradeable, and products yet to be introduced are tweaked for ultimate impact in the market and the proper moment for introduction. Again, a third party market assessment can provide insight into this critical process for the manufacturer.

11. Validate any changes - If significant changes are made in the product make-up as a result of this product tweaking, it will be necessary to redo modeling and experimentation to validate these changes prior to giving the go-ahead to manufacturing.

12. Document and qualify the manufacturing process. This will include such things as establishing ISO ready process documentation including paper trails for change orders and quality control process documentation.

Polycision can help with each of these steps towards a successful product introduction for your company. Make your development as smooth as possible with least financial risk to your company; contact Polycision today.

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