Wafer-scale-integrated silicon-photonics-based optical switching system and method of forming

A monolithically integrated optical switching system comprising:

• (1) a plurality of input ports (112-1,1 through 112-M,m);
• (2) a plurality of output ports (114-1,1 through 114-N,n);
• and
• (3) a plurality of switch blocks (102) that is arranged to collectively define a switching matrix (118), wherein each switch block is substantially identical and characterized by a first reticle pattern that is no larger than a lithography reticle, the first reticle pattern having a perimeter (120) that includes first (122W), second (122E), third (122N), and fourth (122S) edges, and wherein each switch block includes:
• a first plurality of bus waveguides (116), each having a first width (w1) and extending between a first port (WP) at the first edge and a second port (EP) the second edge, each of the first and second ports including a first coupling portion (704) having a second width (w2) and a first taper region that optically couples the bus waveguide and the first coupling portion, wherein the plurality of first ports is arranged in a first arrangement that defines a first lateral interface (126-1), and wherein the plurality of second ports is arranged in the first arrangement to define a second lateral interface (126-2) that matches the first lateral interface;
• a second plurality of bus waveguides that extends between a third port (NP) at the third edge and a fourth port (SP) at the fourth edge, wherein the plurality of third ports is arranged in a second arrangement that defines a first vertical interface (128-1), and wherein the plurality of fourth ports is arranged in the second arrangement to define a second vertical interface (128-2) that matches the first vertical interface;
• and
• a plurality of switches (120), each switch being operatively coupled with a bus waveguide of the first plurality thereof and a bus waveguide of the second plurality thereof;
• wherein the first pluralities of bus waveguides of each laterally abutting switch-block pair are joined via a pair of lateral interfaces;
• wherein the second pluralities of bus waveguides of each vertically abutting switch-block pair are joined via a pair of vertical interfaces;
• wherein the plurality of switch blocks is arranged such that the switch matrix is operative for optically coupling any input port of the plurality thereof with any output port of the plurality thereof;
• and
• wherein the switching matrix is larger than the lithography reticle.