“We were particularly fortunate to have Peter Thijs on our team. He is a world-renowned specialist in epitaxial growth. That’s the process whereby you grow the optical layers which are at the heart the component being manufactured. As well as research knowledge, we assembled business expertise in turning designs into operational devices.
“Like any high-tech startup, we discussed the different business models we could take. But we quickly saw the huge benefits of what’s called the “foundry model”. Firstly, we had access to the best tools to manufacture the integrated circuits. But, just as important, we had expertise in the entire process from design through to finished production and packaging. And I had built a customer network who needed photonic solutions.”
“This approach meant we had customers from our first day of operation. So Smart Photonics only makes the products using designs from our customers. We are independent. The fact that we don't make our own products means there is no conflict of interest in the market. We've seen this go wrong in the mobile handset market, when Company X was making screens for Company Y, and yet competing with Company Y at the same time.”
“In high-end photonics, we're talking about an extremely costly development process until the chip design is finalized and is then ready for mass-production. We assumed, correctly, that small companies working at the forefront of technology would be reluctant to work with large foundries, especially if there was even a slight chance that their intellectual property could be adapted and later used to compete against them in the market. Likewise, large foundries were not keen to share their key technologies because external customers could become competitors. We could see a situation that was actually slowing down the tipping point of Photonics, rather than building a trusted network.”
We also learned to master the complete process of chip manufacturer, including building close relationships with Europe's best photonics designers and understanding the steps after chips are made. Eindhoven University of Technology, for instance, has developed very accurate precision mechanics to attach external plugs and components, so that the chip can be packaged. They are “photonics production robots”.
“Smart Photonics is expanding its services on September 24th 2015. They are opening the second phase of their manufacturing facility. The epitaxial MOPVE industrial reactor facility is located in a special clean-room located on the High-Tech Campus Eindhoven. The "genes" of an integrated photonics chip are made in this reactor. The lasers, amplifiers, phase-shifter are all formed at this stage; in effect you're turning a piece of Indium phosphide into a component that has functionality. “ “This piece of equipment allows Smart Photonics to scale-up production - the wafers in the research facility are 2-inch, the new facility works with 3-inch. So, chip designs that have been tested and validated in the Nanolab research centre at Eindhoven University of Technology can now be produced in larger quantities at a cheaper unit price.”
“This means that as our photonics customers scale up their production of photonics chips, we can scale-up with them.”
“There are only one or two companies in the world that have such a machine as this. But I believe our unique position is that we're combining these facilities with our trusted expertise for the sole benefit of our customers.”
“Our expertise comes in turning designs into real devices. Our team has a deep understanding of how it works. For example, if you wanted to make a laser with an operating wavelength of 1550 nm, with a specified power, our specialists like Peter Thijs can quickly turn that specification into an epitaxial layer. That sort of expertise is difficult to find, which is why I'm so pleased we've been able to retain and grow the photonics knowledge we started at Philips. It can turn a brain drain into a brain gain for this region of the Netherlands”
“Once this layer stack has been created, then you can etch things away, you may add other materials which we call the over-growth, and you're starting to build the circuit. There are more companies in the world that can do this bit, but I believe we are still unique in offering both the creation process (the early growth) followed by the processing, thinning, and adding the gold contact layers. At that point, we can chop the wafer up into individual chips. We coat certain areas so that the light doesn't leak out in the wrong directions.”
“The equipment to do all this isn't cheap - think in the region of €200 million. That's because you're working with nanotechnology in cleanroom conditions. And the machines to grow and calibrate the chips have to be built to order - you can't order them from a catalogue. They also require regular maintenance.”
“Typically, it takes 4 or 5 years to develop and launch a high-tech product on the European market. The same applies to this new phase for photonics. Because we had equipment and expertise already in place, we were able to quickly develop the proof of concept phase. We have done several experimental runs already, built up a trusted global customer base and this year the first step in indium phosphide chip manufacturing will start.”
“We've been able to build trusted partnerships with some very clever high-tech companies around the world. They make a huge investment in design. And we've invested a lot in the equipment to turn that design into a component. It's means Smart Photonics is more than a factory.” “We have been approached by foreign investors who want us to build a similar facility in their country. We've had to say no. That's simply because just building the machinery isn't enough. The expertise is just as valuable and that's built into the relationship we have built over the years with our customers. So whereas others work FOR their clients, we believe it is more like working WITH them. And, when you're working with designs that often run into the millions, each party needs to have 1000% confidence in the reliability of the other. Yes, I do mean 1000%!”
“We already have around 50 customers across the world, both small and very, very large. Many are preparing the technology infrastructure that global society will use in around 2020. It takes time and vision to make these giant leaps.” “These people no longer just talk about Fibre to the Home (FTTH), these companies are talking about FTTX. It's a world where most devices are going to be connected to the Internet”. “All this will demand at least double the global bandwidth in use today by 2020. This isn't a vague prediction. As Africa and Latin America come on line, their prosperity is linked to exponential growth at this stage. So the demand for mass production is just around the corner.” “Our next phase is to build and design a high capacity photonics chip facility so we can scale with our customers. We have the ambition to be the global player in photonics, repeating the success of other great companies that came out of the “city of inventions”. Everything is in place, including the both the research and manufacturing expertise. The University is already turning out brilliant students who would be ideal for our global venture.”
“So, as we open the doors to phase 2, revealing the pilot manufacturing line, we’re already busy designing a much larger Phase 3 for launch in September 2018! We’ll use the experience gained in the coming year to finalize our designs for the full-scale manufacturing line. Of course, we can never be complacent. But you can see by the smile on my face that these are exciting times to be in the Integrated Photonics Business!”