HIGH-DENSITY FAUs AND OPTICAL INTERCONNECTION DEVICES INCLUDING OPTIMIZED ARRAYS AND RELATED METHODS

A method for fabricating a fiber array unit comprising:

• selecting a plurality of optical fibers that each have a respective cladding diameter;
• determining a maximum fiber core position error for the plurality of optical fibers in a plurality of configurations, wherein for each configuration:
• the plurality of optical fibers are arranged side-by-side in an array such that each optical fiber has a position in the array,
• the plurality of optical fibers are arranged in a different order,
• each optical fiber has a respective fiber core position relative to an ideal core position for that optical fiber to define a respective fiber core position error,
• the ideal core positions are based on each optical fiber of the plurality of optical fibers having an ideal cladding diameter, and
• the maximum fiber core position error is a maximum of the respective fiber core position errors;
• and
• determining a desired order of the plurality of optical fibers that minimizes the maximum fiber core position error
• positioning the plurality of optical fibers on a support substrate in the configuration that comprises the desired order;
• and
• applying an adhesive to affix the plurality of optical fibers to the support substrate.