The core technical objective of OptoWavePro is to create a fully functional prototype of an optical cochlear implant that can restore more natural hearing in people with severe hearing loss. The work focuses on integrating three key components into a compact implant: a high-density laser diode array, custom microlens arrays for directing laser beams, and biomedical-grade polymer waveguides that deliver light to targeted neurons in the cochlea. These are assembled into a robust hermetic titanium package designed to meet clinical and surgical requirements.
Modulight leads development of custom flip-chip laser arrays, each with up to 64 emitters spaced at 100 micrometers. The design ensures efficient coupling into optical channels, producing narrow beams while minimizing heat and stray light. Alternative top-side mounting options have been explored to improve reproducibility and reduce fabrication risks.
Efficient light delivery requires advanced incoupling optics. The team designed fused silica microlens arrays, each lens paired with a laser diode to collimate and focus light into millimeter-scale waveguides. A bi-convex geometry optimizes alignment and minimizes crosstalk. Automated alignment tools enable micron-level precision during assembly. Optical simulations confirmed the chosen setup balances efficiency, uniformity, and manufacturability.
Polymer waveguide development centers on biocompatible Parylene, suited for long-term implantation. Researchers used both direct patterning and wafer-scale casting to enable mass production. The waveguides incorporate features like slanted mirrors and total internal reflection prisms to redirect red light along the cochlea toward optogenetically sensitized neurons. Early process optimization included material testing, surface roughness analysis, and refractive index measurements to ensure optical clarity, mechanical resilience, and reliable channel isolation.
Integrating the optical and electronic components into a clinical-grade device required extensive engineering. The titanium case incorporates a sapphire window, gold-brazed to a titanium flange, ensuring both high light transmission and hermetic sealing. Its design includes a flat return, step structure, and dimensional tolerances to support automated assembly. Hermeticity and photometry tests validated the feedthrough, while internal titanium posts protect sensitive optical components from shock and vibration.
In summary, OptoWavePro has achieved major milestones: Validated laser arrays, microlens systems, and high-performance waveguides, all integrated into a sealed clinical package. Combined with preclinical validation, digital quality control, and ongoing regulatory planning, the project is well positioned to move toward clinical translation and market impact.
