The high-density FAU comprises a support substrate having a grooved front-end section that supports glass end sections of the small diameter low-attenuation optical fibers. A cover is disposed on the front-end section and secured thereto to hold the glass end sections in place. The substrate and the cover can be made of the same glass or glasses having about the same CTE. The glass end sections have a diameter d4 so that the pitch P2 of the fibers at the front end of the FAU can be equal to or greater than d4, wherein d4=2r.sub.4, with r.sub.4 being the radius of the glass end section as defined by the optical fiber cladding. The glass end section has a radius r.sub.4 less than 45 microns, allowing for a high-density FAU and a high-density optical interconnection device.

A passively aligned fan-out apparatus for a multicore fiber (MCF) includes a fan-out assembly that comprises a fan-out substrate, small-clad fibers (SCFs) supported in SCF V-grooves of the fan-out substrate, and alignment rods disposed outboard alignment V-grooves of the fan-out substrate. The SCFs have a distal-end pitch P2D at a distal end of the fan-out substrate greater than the proximal-end pitch P2P of the SCFs at a proximal end of the fan-out substrate. An MCF assembly and/or single mode fiber (SMF) assembly may also be provided as part of the fan-out apparatus.

Embodiments disclosed herein include optical connectors for photonic packages. In an embodiment an optical connector comprises a socket and a ferrule inserted into the socket. In an embodiment, the optical connector further comprises a first row of optical fibers in the ferrule, and a second row of optical fibers in the ferrule over the first row. In an embodiment, the optical connector further comprises a fiber distribution housing where the first row of optical fibers and the second row of optical fibers are spread laterally within the fiber distribution housing.

An optical fiber fan-out assembly includes multiple optical fibers arranged in a one-dimensional array in a transition segment in which spacing between fibers is varied from a first pitch (e.g., a buffered fiber diameter of 900 μm) to a second pitch (e.g., a coated fiber diameter of 250 μm). A polymeric material encapsulates the optical fibers in the transition segment, and the assembly further includes multiple optical fiber legs each terminated with a fiber optic connector. Optical fibers extending beyond a boundary of the polymeric material are subject to being mass fusion spliced to another group of multiple optical fibers, and the fusion splices encapsulated with polymeric material, to form a fiber optic cable assembly. Methods for fabricating multi-fiber assemblies providing fan-out functionality are further provided, and the need for furcation tubes is avoided.

An optical fiber arranging tool has a base, a top surface, and a recessed channel extending along the base and has a plurality of ribs disposed within the recessed channel. The plurality of ribs have a pitch of 250 microns creating a plurality of grooves for receiving the optical fibers. The tool may also have a latch extending from the top surface of the base on one side of the recessed channel and across the recessed channel to a second side of the recessed channel, there being a slot between the top surface of the base and an underside of the latch and in communication with the recessed channel. A method for aligning the optical fibers at a pitch that is larger than the outer diameter of the optical fibers includes sliding individual optical fibers one by one into slot and the recessed channel, moving an object along the optical fibers in the recessed channel, passing the individual optical fibers through a respective one of a plurality of grooves created by ribs within the recessed channel and maintaining the individual optical fibers at a distance of 0.250 mm at an end of the recessed channel.

An optical transceiver includes an input assembly, an output port, a fiber patch panel, multiple first optical fibers and multiple second optical fibers. The input assembly is arranged on a circuit board and has a first input port and a second input port. The fiber patch panel is arranged between the input assembly and the output port, and has multiple first fiber patch slots and multiple second fiber patch slots. The first optical fibers are connected to the first input port and the output port. The first optical fiber passes through the first fiber patch slot and the second fiber patch slot. The second optical fibers are connected to the second input port and the output port. The second optical fiber passes through the first fiber patch slot and the second fiber patch slot. The second fiber patch slot accommodates the first optical fiber and the second optical fiber.

Waveguide connector assemblies having a clamshell shell housing and methods of assembling a waveguide module assembly are disclosed. In one embodiment, a waveguide module assembly includes a first shell housing, and a second shell housing coupled to the first shell housing. The first shell housing and the second shell housing define a cavity. The waveguide module assembly further includes a waveguide substrate including at least one waveguide, a first surface, and a second surface opposite the first surface. The waveguide substrate is at least partially disposed within the cavity such that at least a portion of the first surface and at least a portion of the second surface are covered by at least one of the first shell housing and the second shell housing.

An optical fiber arranging tool has a base, a top surface, and a recessed channel extending along the base and has a plurality of ribs disposed within the recessed channel. The plurality of ribs have a pitch of 250 microns creating a plurality of grooves for receiving the optical fibers. The tool may also have a latch, there being a slot between the top surface of the base and an underside of the latch and in communication with the recessed channel. A method for aligning the optical fibers includes sliding individual optical fibers into a slot and the recessed channel, moving an object along the optical fibers in the recessed channel, passing the individual optical fibers through a respective one of a plurality of grooves created by ribs within the recessed channel and maintaining the individual optical fibers at a distance of 0.250 mm.

A fixture is for forming a fiber optic array that defines a plurality of discrete fibers extending from a spaced-apart arrangement to a consolidated arrangement wherein the fibers are layered next to each other for a further ribbonizing process. The fixture includes a pair of contact blades that are configured to slide along a direction transverse to the longitudinal axes of the fibers for consolidating the fibers.

A method for manufacturing a fan-in-fan-out device which does not require processing of a small-diameter hole and improves work efficiency of installation of an optical fiber, includes: arranging a first holding member in a hole of a second holding member, the hole being larger than an outer diameter of the first holding member, and holding a plurality of optical fibers between the first holding member and the second holding member respectively along a plurality of grooves formed on an outer periphery of the first holding member or an inner periphery of the hole of the second holding member; heating and integrally melting the arranged first holding member, the plurality of held optical fibers, and the second holding member in a portion including an axial end portion of the second holding member; and drawing the melted portion.