Precision TFF POSA and WDM systems using parallel fiber interface devices

A precision passive optical structure assembly (POSA) formed by the process comprising:

• forming respective thin film filters on respective first surfaces of two or more glass rods using a thin-film deposition process, wherein:
• each of the two or more glass rods also has a second surface substantially parallel to the first surface,
• each of the thin film filters has a thickness variation due to curvature of an optical surface of the thin film filter that is opposite the first surface of the corresponding glass rod, and
• the thin film filters have different non-overlapping wavelength transmissions;
• forming a glass rod assembly comprising the two or more glass rods arranged side-by-side so that the thin film filters reside in a common plane;
• arranging the glass rod assembly on a top surface of a master glass block with the thin film filters confronting the top surface;
• pressing the glass rod assembly and the master glass block together with a securing material therebetween to substantially reduce the amounts of curvature of the optical surfaces of the thin film filters;
• securing the glass rod assembly to the master glass block with the securing material while the thin film filters have said substantially reduced amounts of curvature;
• and
• singulating the glass rod assembly and the master glass block after said securing, in a plane transverse to the first direction, to form the precision POSA.

A method of forming multiple precision passive optical structure assemblies (POSAs) for wavelength-division multiplexing (WDM) applications, comprising:

• forming respective thin film filters on respective first surfaces of at least four glass rods using a thin-film deposition process, wherein:
• each of at least four glass rods also has a second surface substantially parallel to the first surface,
• each of the thin film filters has a thickness variation due to curvature of an optical surface of the thin film filter that is opposite the first surface of the corresponding glass rod, and
• the thin film filters of the at least four glass rods have different non-overlapping wavelength transmissions;
• forming a glass rod assembly comprising the at least four glass rods arranged side-by-side so that the thin film filters reside in a common plane;
• arranging the glass rod assembly on a top surface of a master glass block with the thin film filters confronting the top surface, wherein the master glass block is elongate in a first direction;
• pressing the glass rod assembly and the master glass block together with a securing material therebetween to substantially reduce the amounts of curvature of the optical surfaces of the thin film filters;
• curing the securing material during said pressing to fix the glass rod assembly in place on the master glass block with the thin film filters having the substantially reduced amounts of curvature;
• and
• after said curing, singulating the glass rod assembly and the master glass block into multiple sections to form the multiple precision POSAs, wherein said singulating is along planes transverse to the first direction.