IN THE NEWS

Ion beams light way for 4Wave fab process

By Garry Kranz
Small Times Correspondent

August 16, 2004 – 4Wave Inc. wants to prove that its small technology is no optical illusion.

Applying a precision technique known as ion sputtering, Sterling, Va.-based 4Wave produces atomically thin films used for making next-generation optical chips. The 4Wave chips integrate four distinct optical filters and a reflective mirror on a flat glass surface.

The single-chip architecture is the foundation for a miniaturized version of an optical component known as a coarse wave division multiplexer (CWDM). The fabrication process produces coatings of no more than a few nanometers.

Potential customers include optical equipment makers. This especially includes transceiver makers, who are under increasing pressure to miniaturize their components to meet stringent new standards for Ethernet equipment adopted last year by the Institute of Electrical and Electronics Engineers.

4Wave already sells its technology to companies in the magnetic data-storage and semiconductor industries. Sami Antrazi, 4Wave president, lists IBM, Hitachi, Gillette, and Seagate among the firm’s customers.

“We are not known in the optical industry, so we needed to develop a disruptive technology to penetrate the market,” said Antrazi.

Demand for CWDMs is expected to skyrocket as 10GB Ethernet matures. ElectroniCast, a San Mateo, Calif.-based research firm, predicted sales of 10GB Ethernet transceivers to top $9 billion worldwide by 2010.

Massive amounts of unused fiber optic cable lie unused across the country, especially in metropolitan areas. Making use of it, however, is expensive. Cumbersome electronics must be installed, or worse, the cable must be ripped out from the ground. “That’s where we think we can add value,” says Trey Middleton, 4Wave’s business development director.

4Wave patented its fabrication process, known as Bias Target Ion Beam Deposition, helped by a grant of nearly $2 million from the National Institute of Science and Technology.

Hitachi Global Storage Technologies of San Jose, Calif., is using 4Wave’s fabrication method to produce thin films for applications related to magnetic data storage.

“We haven’t taken it into production yet, but we are hoping the system will help us,” said Danielle Mauri, a senior process engineer for Hitachi. “We are studying how it helps us grow smooth layers, which is critical for what we do.” The next step for 4Wave is to refine the process to enable large-scale manufacturing. Ramping up, however, presents different challenges, namely finding investors.

The company’s original plans called for raising capital in 2002, but it’s been tough sledding. Skittish investors are especially shying away from optics-related ventures. “With an infusion of $2 million to $3 million, we could be up and running making these coatings now,” said 4Wave’s Middleton.

Meanwhile, the company continues marketing its system. It posted a profit of $120,000 on revenues of $1.6 million in 2004. All profits were reinvested in the company, said Antrazi.