Passive alignment with optical fibers using ferrule member

An apparatus, comprising:

• a substrate defining a top surface, a channel, and first and second alignment faces arranged at opposing ends of the channel relative to a first dimension, wherein the first and second alignment faces include first and second deformable members extending into the channel and arranged at opposing ends of the channel relative to the first dimension;
• and
• a ferrule member defining at least one opening having an optical fiber extending therethrough,
• the ferrule member having one or more lateral surfaces that slidingly engage with the top surface of the substrate to align the optical fiber in a second dimension when an engagement portion of the ferrule member is inserted into the channel,
• the engagement portion defining first and second contours at opposing ends thereof, the first and second alignment faces configured to align the ferrule member in the first dimension by deforming to engage the first and second contours during insertion of the engagement portion, thereby aligning the optical fiber in the first dimension.

A method of making an apparatus for passive alignment of at least one optical fiber extending through an opening of a ferrule member, the method comprising:

• forming a channel from a top surface of a substrate, the channel dimensioned to receive an engagement portion of the ferrule member, the top surface configured to engage with one or more lateral surfaces of the ferrule member when the engagement portion is received into the channel;
• and
• forming, at opposing ends of the channel relative to a first dimension, first and second alignment faces configured to engage with first and second contours at opposing ends of the engagement portion to thereby limit motion of the ferrule member in the first dimension,
• wherein the engagement of the first and second contours with the first and second alignment faces aligns the optical fiber in the first dimension, and wherein engaging the top surface with the one or more lateral surfaces aligns the optical fiber in the second dimension.