A multiple 32-fiber array connection method with low loss and high sta
bility is developed for silica-based planar lightwave circuits (PLC's)
on Si. This technique is realized by fabricating a 32-fiber array wit
h high pitch accuracy and reducing the warp of the chip. The average c
onnection loss of a module connected to four 32-fiber arrays is 0.3 dB
/point and the average loss change in a temperature cycle between 75 a
nd -40 degrees C is less than 0.1 dB. Moreover, the module insertion l
oss was stable for 1200 h at 75 degrees C and 90% RH. These results sh
ow that the technique is suitable for practical applications.