Two different methods of pattern replication (conventional and interla
ced fan-out) have been investigated and experimentally tested in a rec
onfigurable 5x5 optical interconnect. Similar alignment problems due t
o imaging errors (field curvature) were observed in both systems. We c
onclude that of the two methods the interlaced fan-out is better suite
d to avoid these imaging errors, to reduce system size and to implemen
t an optical feedback loop.