1. Actuator – Focal Plate Integration Round 1 2011-03-02 Silber / Bebek

2. Back Insertion

3. Front Insertion

4. “Wedge” 28 actuators per wedge Combine into a single 32-fiber connector (and single power connector)

5. Fiberbot

6. Coupled Integration Issues (1 of 2) IssueOptionsTightly coupled with… Insertion DirectionFront Back Fiber Grouping Fiber Handling During Install Fiber Threading Thru Actuator Focal Plate Form Replacement of Actuators / Fibers Fiber GroupingConnector per fiber Block connector (28-32x fibers) after FP integration Block connector (28-32x fibers) before FP integration Insertion Direction Power / Electronics Grouping Fiber Threading Thru Actuator Fiber Handling During Install Focal Plate Form Replacement of Actuators / Fibers Power Cables / Buses GroupingDangling cable per actuator Cable grouping (28-32x cables) Fiber Grouping Replacement of Actuators / Fibers Electronics GroupingBoard per actuator Board per group of actuators (28-32x) Ferrule Z PositioningFerrule z-stop Microscope and clamp Z Tolerance Stackup Integration Tooling Pre- / Post-integration Metrology Replacement of Actuators / Fibers Actuator Z PositioningActuator z-stop Actuator z-stop with shims Microscope and clamp Fiber Handling During InstallBend / twist protection device Trust the techs… Extra length (for easier handling) Less length (for less to “trip over”) Insertion Direction Fiber Grouping Fiber Threading Thru Actuator Integration Tooling Replacement of Actuators / Fibers Fiber Threading Thru ActuatorBefore FP integration After FP integration During FP integration During FP integration + final actuator assembly step Insertion Direction Fiber Grouping Fiber Handling During Install Replacement of Actuators / Fibers

7. Coupled Integration Issues (2 of 2) IssueOptionsTightly coupled with… Z Tol. Stackup, FP to Fiber TipFerrule z-stop + Actuator z-stop Ferrule z-stop + Actuator z-stop + Graded Shims Microscope Adjustment Microscope Adjustment + “Wedge” Mounting Ferrule Z Positioning Actuator Z Positioning Focal Plate Form Pre- / Post-integration Metrology Focal Plate FormFlat Spherical Flat Subdivided (wedges) Spherical Subdivided (wedges) Insertion Direction Fiber / Power / Electronics Grouping Z Tolerance Stackup Integration Tooling Pre- / Post-integration Metrology Replacement of Actuators / Fibers Integration ToolingManual insertion + manual z-adjustment Robot insertion + manual z-adjustment Robot insertion + robot z-adjustment Ferrule / Actuator Z Positioning Fiber Handling During Install Focal Plate Form Pre-integration MetrologyCMM of FP CMM of FP + “gauge blocking” of every actuator CMM of FP + statistical sample of some actuators Ferrule / Actuator Z Positioning Z Tolerance Stackup Focal Plate Form Ferrule / Actuator Z Positioning Z Tolerance Stackup Focal Plate Form Post-integration MetrologyCMM of feature on ferrules possible? Robot with microscope on fiber tips? Replacement of ActuatorsDuring integration “One year later” Insertion Direction Fiber / Power / Electronics Grouping Ferrule / Actuator Z Positioning Fiber Handling During Install Fiber Threading Thru Actuator Focal Plate Form Post-integration Metrology Replacement of FibersDuring integration “One year later”

8. Best method for mapping out various plausible configurations? Configuration OptionsImplications Insertion Direction Fiber Grouping Electronics Grouping etc. Estimated Z Tol. Stackup Risks Front11…1µm Connector density, … Front281…0.3µm Connector groupalizing, … Front28 …100µm Bigfoot, Godzilla, … Back281…1mm… Back28 …0.231Mm… etc………………