The first few years I worked at Bell Labs involved late analog and early digital transmission technology... for example, microwave routes using TD-2 radio technology, long-haul L-carrier coaxial cable systems, FDM and TDMA satellite links and short-haul T1 carrier. But soon thereafter, and ever since, I’ve been involved with fiber-optic transmission technology, first asynchronous, then SONET/SDH, PON systems, Gigabit Ethernet, 10-Gig Ethernet, etc. In the last 10 years, much of my work on fiber optics has been at layer 1... cable, connectors and components.
With my physics background, I tend to think of optical technology as a natural extension of radio technology, just at higher frequency... so the full richness of electro-magnetic propagation through anisotropic materials is quite natural for me. But what I’ve learned, is that complex as optical science is, the really difficult problems from an engineering perspective come down to two disciplines: mechanical engineering and materials. This took me a long time to fully appreciate.
Optical technology is difficult mechanical engineering because optical wave lengths are very short compared to traditional fabrication tolerances. Consequently, fractions of a micron matter... most transmission lasers have wavelengths in the 0.8 to 1.6 micron range. Also, cleanliness matters and process reproducibility matters. In retrospect, it is amazing that optical connectors, assembled by hand, work as well as they do. This was the result of designs that embedded tight tolerance components (ferules and fibers) inside lower tolerance connector components. Equally important are connector assembly processes that rigorously controlled and tested.
The second discipline, materials design, is so pervasive as to be invisible to many people. The optical properties of glasses, coating materials, buffer and cabling materials, epoxies, ferule materials, laser materials, detector materials, abrasives, cleaning materials... it all matters. The inherent variability of these materials choices is enormous and when you combine them together in a system... you can generate astronomical complexity. This complexity is both a curse (how do you control them all) and a blessing (plenty of opportunity to improve designs.)
How do you create differentiated products in the optical space? Great mechanical designs, protected by patents, are the first step. These are necessary, but not sufficient, because it is easy enough to engineer around particular patents. Process trade secrets are the second step, providing better protection because it is much more difficult to determine them by inspection of the product. But, trade secrets can also be lost to you or leaked to competitors as employees come and go. The third step is getting access to custom materials, special formulations of materials that enhance the performance of mechanical designs and process improvement. If all three components of this differentiation strategy are working well together, then your optical product will be strongly differentiated in a number of performance dimensions: cost, optical parameters, reliability, etc. and that differentiation should be sustainable.
What are your thoughts on optical technology and product differentiation in this space? Do you disagree with my elevation of mechanical and materials engineering above electrical and optical engineering disciplines?
Thanks Mike for a very interesting post. I really enjoyed reading it.
ReplyDeleteI completely agree with your synopsis. Not to minuscule the role of electrical and optical engineers in the future development of optical communications, but in my humble opinion, the challenges put forth by the materials, interface design and assembly processing over others are far more complex and thus place mechanical and material engineering at the fore front.
Interestingly, just the other day, I was reading about Intel- developed optical technology that carries data signals inside the computer systems. If not cost prohibitive and industry adopted, this game-changer will replace current conventional systems that transmit/process information in serial form, reduce latency and result in faster-than-ever-before data movement and processing. New materials and interface components (specifically cables, connectors) that ensure low attenuation are critical for this development. Both require engagement from mechanical and material engineers.
To create differentiation, I believe one needs to develop products with best-in-class performance, long term reliability and at cheapest cost possible. Also important to consider is human factors. This is a very dynamic industry, where you have to be embedded in your customer base, keep an ear to the ground and drive new requirements. With all its challenges, complexity and fast pace; there is no other industry I would rather be. I am loving every second of this party.
Disclamier: Author is a Mechanical Engineer by training and his opinions could be biased.