Highly dense multimode fiber bundles

The growing demand for high-bandwidth and energy-efficient data transfer in large-scale computing systems has increased interest in various optical interconnect technologies. Highly dense multi-mode fiber bundles could be an important component. These interconnects require precise fiber positioning to minimize signal loss and crosstalk, which becomes increasingly challenging as bundle size and fiber count scale. In this work, the limitations of conventional assembly methods that rely on fiber diameter tolerances and their impact on grid accuracy are examined. Experimental measurements and optical simulations were performed to characterize crosstalk sensitivity to misalignment, revealing that displacements of individual fibers beyond approximately 5 μm could significantly affect performance. Bundle coherence measurements are described, demonstrating fiber bundle ability to transmit image. Grid accuracy has been analyzed in large bundles and it was demonstrated that achieving sub-5 μm accuracy using traditional stacking methods requires extremely tight fiber tolerances (