While optical fiber and photonic technology is the cost-effective means for long-haul, high bandwidth communication, component cost alone has precluded the wide spread deployment of similar technologies at the frame level due to the large number of interconnections required. The need to overcome limitations of electrical interconnection when the data rate exceeds several hundred Mb/s now demands the use of photonic technology over a distance of 10-100 cm. Thus, frame-level (intra-system) optical interconnection within high capacity electronic systems has seen substantial growth in the past few years[ 1,2].Planar and channel glass or polymer waveguides have been considered for optical interconnection on a module or board scale [3]. However, optical loss alone (0.1-1.0 dB/cm) would have precluded their application to the inter-board and inter-shelf, or backplane interconnection level (i.e. over lengths up to 20 inches). Free-space optics, including holographic means of using lenses, mirrors, etc to direct optical signals requires novel physical design and will probably result in non-standard hardware packaging. Therefore, optical fiber continues to be the most widely accepted medium of transmitting optical signals. For applications within equipment, the main challenge is to develop automated manufacturing technologies dealing with short fiber lengths and to manage them as a robust, organized fabric.Using discrete wiring technology, rigid boards incorporating both electrical wires and polyimide-coated optical fibers have been demonstrated [4]. However, the ultrasonic bonding technique used damages other softer polymer coatings on optical fibers, thereby creating reliability issues. The need to use standard telecom fibers with acrylate coatings led us to develop a different manufacturing technology, which can handle a variety of optical fibers and to fabricate rigid and/or flexible optical circuits. The degree of automation achieved permits precise control both of fiber placement to form multifiber ribbons and fiber lengths to form skew-free interconnections. This is especially important as array devices become increasingly used within systems [5].To be compatible with existing electronic packaging hardware, we have focused on the development of flexible optical circuits, known as OptiFlexTM within AT&T. Such circuits represent an add-on structure that could mount within the electrical frames and cabinets. Using thin tabs that bend and flex the fibers into connector housings, we have overcome a major physical design issue of ninty-degree coupling between the circuit boards and backplane in the conventional orthogonal packaging scheme. The AT&T process begins with a CAD design using common software packages such as AutoCAD and VersaCAD on a PC platform. We have developed a set of design rules for laying out the fiber arrangement. These rules provide the proper limits on bend radius, fiber spacing, intersection angles, cross-overs, and other circuit parameters. When the layout design is complete, a custom-developed con...