Laser processing of an optical fiber to alter the end face shape for insertion into optical connectors

Abstract

The present disclosure relates to laser processing an optical fiber to shape an end face of the optical fiber where the optical fiber is inserted into an optical connector. The optical connector comprising a ferrule having a fiber guide element that includes a guide section and a neck section. The end face is shaped to be rounded such that a core of the optical fiber extends into the neck section of the ferrule of the connector.

Description

Attorney Docket No.: HI24-110PCTLASER PROCESSING OF AN OPTICAL FIBER TO ALTER THE END FACE SHAPE FOR INSERTION INTO OPTICAL CONNECTORSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 704,882, filed on October s, 2024, the content of which is relied upon and incorporated herein by reference in its entirety.FIELD OF THE DISCLOSURE

[0002] This disclosure relates generally to laser processing an optical fiber and more particularly, to laser processing an optical fiber to shape the end face of the optical fiber for insertion into an optical connector.BACKGROUND OF THE DISCLOSURE

[0003] Optical fibers are useful in a wide variety of applications, including the telecommunications industry for voice, video, and data transmissions. In a telecommunications system that uses optical fibers, there are typically many locations where fiber optic cables that carry the optical fibers connect to equipment or other fiber optic cables. To conveniently provide these connections, fiber optic connectors are often provided on the ends of fiber optic cables. The process of terminating individual optical fibers from a fiber optic cable is referred to as "connectorization." Connectorization can be done in a factory, resulting in a "pre-connectorized" or "pre-terminated" fiber optic cable, or the field (e.g., using a "field- installable" fiber optic connector).

[0004] A costly and time consuming step in processing and connectorizing optical fibers is mechanically polishing the fiber end face. In some automated processes, there are several polishing steps needed to produce end faces of sufficient quality and low mating loss. This polishing method can leave debris at each step and a final cleaning step is needed to ensure cleanliness of the end face. To mechanically polish, the optical fiber is first inserted into and bonded to or held in a ferrule. Then, the optical fiber is mechanically polished. Alternatively, by using laser polishing, the mechanical polishing can be eliminated and the polishing of the optical fiber can be completed prior to inserting and bonding in the ferrule. Historically, laser polishing has been used as a cost and processing time saver.Attorney Docket No.: HI24-110PCT

[0005] In addition, when optical fibers are inserted into ferrules without prior laser processing, the edges of the optical fiber can contact the guiding features of the ferrule bore of the connector. This contact can create loose debris, which can damage the ferrule end face or obstruct the end face and thereby inhibit the connectivity of the inserted optical fiber. Additionally, installation is slower due to the desire to limit debris production.

[0006] As such, laser processing optical fibers is needed and desired to reduce cost, to reduce processing time, and to improve connectivity.SUMMARY OF THE DISCLOSURE

[0007] The present disclosure relates to laser processing an optical fiber to shape an end face of the optical fiber where the optical fiber is inserted into an optical connector. The optical connector comprising a ferrule having a fiber guide element that includes a guide section and a neck section. The end face is shaped to be rounded such that a core of the optical fiber extends into the neck section of the ferrule of the connector.

[0008] In one embodiment, an optical connector assembly is provided. The optical connector assembly comprising: a ferrule comprising: a fiber guide element comprising a guide section and a neck section that extends from the guide section and that has a diameter that is less than a diameter of the guide section; wherein a stop is defined at an interface of the guide section and the neck section; and a light input surface adjacent the neck section of the fiber guide element; an optical fiber positioned in the fiber guide element of the ferrule, the optical fiber having a rounded end face extending into the neck section beyond the stop.

[0009] In another embodiment, the optical fiber end face has a radius of curvature ranging between about 1 micron and about 50 microns. In another embodiment, the optical fiber end face is spaced from the light input surface of the fiber guide element by a distance D3 ranging between about -10 microns and about 10 microns relative to the stop. In another embodiment, the optical fiber comprises a core that is positioned beyond the stop of the fiber guide element. In another embodiment, the optical fiber is inserted into the ferrule at an angle ranging between about 5° and about 20° relative to an axis of the ferrule. In another embodiment, the fiber guide elements are V-grooves.

[0010] In one embodiment, an optical connector assembly is provided. The optical connector assembly, comprising: a ferrule including a plurality of fiber guide elements and a light coupling portion adjacent the plurality of fiber guide elements, wherein: each fiber guide element of theAttorney Docket No.: HI24-110PCT plurality of fiber guide elements includes a guide section and a neck section that extends from the guide section and that has a smaller width than the guide section, a stop defined in each of the fiber guide elements at an interface of the guide section and the neck section, and the light coupling portion includes a light input surface facing the plurality of fiber guide elements; and a plurality of optical fibers each positioned in a respective fiber guide element of the plurality of fiber guide elements, wherein: each optical fiber of the plurality of optical fibers includes a rounded end face that extends into the neck section of the associated fiber guide element and that is spaced from the light input surface, at least one optical fiber of the plurality of optical fibers does not contact the stop of the associated fiber guide element, and at least one optical fiber of the plurality of optical fibers contacts the stop of the associated fiber guide element.

[0011] In another embodiment, each optical fiber of the plurality of optical fibers is positioned so that the rounded end face is spaced from the light input surface by a respective gap distance, and wherein the respective gap distances are within a range of about 1 microns and about 10 microns of each other. In another embodiment, each optical fiber of the plurality of optical fibers is positioned so that the rounded end face is spaced from the light input surface by a respective gap distance, and wherein the respective gap distances are within a range of about 5 microns and about 10 microns of each other. In another embodiment, the rounded end faces are spaced from the light input surface by a distance D3 ranging between about -10 microns and about 10 microns relative to the stop. In another embodiment, the fiber guide elements are V-grooves.

[0012] In one embodiment, a method of processing an optical fiber for insertion into an optical connector that comprises a ferrule having a fiber guide element comprising: a guide section and a neck section that has a diameter that is less than a diameter of the guide section; wherein the neck section extends from a stop to a lens at an end of the fiber guide element, wherein the stop is at an interface of the guide section and the neck section is provided. The method comprising: laser cleaving the optical fiber; laser processing an end face of the optical fiber, wherein the optical fiber has a rounded end face; inserting the optical fiber into the fiber guide element of the optical connector, wherein the rounded end face extends into the neck section beyond the stop.

[0013] In another embodiment, the optical fiber end face has a radius of curvature ranging between about 1 micron and about 50 microns. In another embodiment, the optical fiber end face is spaced from the light input surface of the fiber guide element by a distance D3 rangingAttorney Docket No.: HI24-110PCT between about -10 microns and about 10 microns relative to the stop. In another embodiment, the optical fiber comprises a core that is positioned beyond the stop of the ferrule. In another embodiment, the optical fiber is inserted into the ferrule at an angle ranging between about 5° and about 20°relative to an axis of the ferrule. In another embodiment, the optical fiber is laser cleaved prior to insertion into the ferrule, wherein the optical fiber is cleaved at an angle of about 8° relative to a longitudinal axis of the optical fiber. In another embodiment, the fiber guide elements are V-grooves.

[0014] Additional features and advantages will be set out in the detailed description which follows, and in part will be readily apparent to those skilled in the technical field of optical connectivity. It is to be understood that the foregoing general description, the following detailed description, and the accompanying drawings are merely exemplary and intended to provide an overview or framework to understand the nature and character of the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the description serve to explain principles and operation of the various embodiments. Features and attributes associated with any of the embodiments shown or described may be applied to other embodiments shown, described, or appreciated based on this disclosure.

[0016] FIG. 1 shows an optical connector assembly housing a ferrule according to some aspects of the disclosure; and

[0017] FIG. 2 is a perspective view of a ferrule within the optical connector assembly of FIG. 1;

[0018] FIG. 3 is a schematic cross-sectional view of an optical connector within the optical connector assembly of FIG. 1;

[0019] FIG. 4A is a schematic cross-sectional view of coupled optical connector assemblies including optical connectors of FIG. 2;

[0020] FIG. 4B is a schematic illustration of the light path through the coupled optical connector assemblies of FIG. 4A;Attorney Docket No.: HI24-110PCT

[0021] FIG. 5A is a perspective view of the ferrule of FIG. 2 illustrating optical fibers being inserted into the ferrule;

[0022] FIG. 5B is a top view of the ferrule of FIG. 2 with optical fibers inserted into the ferrule; and

[0023] FIGS. 6A and 6B are enlarged views of a neck section of the ferrule that illustrate the difference in fiber positioning between optical fibers that have been laser processed in accordance with the present disclosure and optical fibers that have not been laser processed.DETAILED DESCRIPTION

[0024] Various embodiments will be clarified by examples in the description below. In general, the present disclosure relates to laser processing an optical fiber to shape an end face of the optical fiber where the optical fiber is inserted into an optical connector. The optical connector comprising a ferrule having a fiber guide element that includes a guide section and a neck section. The end face is shaped to be rounded such that a core of the optical fiber extends into the neck section of the ferrule of the connector.

[0025] Referring to FIG. 1, an optical connector assembly 100 is shown. The optical connector assembly 100 includes a connector housing 101 having a mating end 103 and an opposite fiber end 105. In some embodiments, the connector housing 101 may have a unitary construction. In some embodiments, the connector housing 101 may be made from a glass fiber reinforced resin.

[0026] The connector housing 101 is configured to house a ferrule 110 as shown in FIG. 1. The connector housing 101 is also configured to prevent dirt from interfering with optical connections, for example. The connector housing 101 may also provide, in some embodiments, retention force to maintain the ferrules in positive contact, as well as a latching and release mechanism for mating and un-mating an optical connector. In addition, the connector housing 101 can protect a ferrule from outputting stray light that can be a safety hazard to those nearby. In some embodiments, the housing may have a latching mechanism to prevent its accidental opening. In some embodiments, the housing may have a door mechanism that may be opened by the action of mating two connectors. The housing can have any suitable configuration for holding and securing the ferrule 110 and for mating the optical connector to the mating optical connector.Attorney Docket No.: HI24-110PCT

[0027] As mentioned previously, a ferrule 110 is housed within the connector assembly 100. Referring now to FIG. 2, ferrule 110 includes a mating end 111, a fiber attachment area 113 where optical fibers 115 are attached, and a light coupling portion 118 adjacent to the fiber attachment area 113. An optical fiber 115 may include, for example, a single or multi-mode waveguide, a single core optical fiber, a multi-core optical fiber, a polymeric waveguide, or planar waveguides disposed on a substrate. For ease in discussion, the term "optical fiber" will be used. The fiber attachment area 113 may be disposed between the mating end 111 and an opposite fiber end 117 of the ferrule 110.

[0028] One or more optical fibers 115 may be disposed at the fiber ends 105, 117 of the connector housing 101 and the ferrule 110. The optical fiber 115 may include at least one corresponding fiber end 131 fixedly attached to the attachment area 113 of the ferrule 110.

[0029] Ferrule 110 also comprises a plurality of fiber guide elements 121 within the attachment area 113 and adjacent to light coupling portion 118 (light coupling portion 118 facing the plurality of fiber guide elements 121). The plurality of fiber guide elements 121 are configured to provide a channel by which optical fibers 115 can be inserted into and organized within ferrule 110. Each of the plurality of fiber guide elements 121 comprise a guide section 123 and a neck section 125 adjacent to the guide section 123. As shown, guide elements 121 are continuous where the guide section 123 and neck section 125 interface at a stop 127. At stop 127, neck section 125 extends from the guide section 123 and tapers until an end wall or light input surface 129 of light coupling portion 118, which is spaced from a light redirecting surface 119. Guide section 123 has a width Wl, and neck section 125 has a width W2 (FIG. 5B) that is less than the width Wl (FIG. 5B) of the guide section 123. In some embodiments, fiber guide elements 121 are V-grooves.

[0030] As shown in FIG. 3, light coupling portion 118 comprises light input surface 129, light redirecting surface 119, and a light output surface 137. Light input surface 129 is spaced from the stop 127 (FIG. 6A) and faces the plurality of fiber guide elements 121 as shown in FIG. 3. Light redirecting surface 119 of the ferrule 110 is disposed between the mating end 111 and the fiber attachment area 113 and is configured to collimate the light emitted from the optical fiber 115. For example, the light redirecting surface 119 may include one or more of a prism, a lens, and a reflecting surface, such as a mirror or the like, to collimate light.Attorney Docket No.: HI24-110PCT

[0031] With continued reference to FIG. 3, a cross-sectional view of ferrule 110 is shown with an optical fiber 115 inserted or landed into the attachment area 113 as discussed in greater detail herein. As shown, a light ray 107 is directed through optical fiber 115 and through light input surface 129 of light coupling portion 118. Light ray 107 continues beyond light input surface 129 of ferrule 110 to light redirecting surface 119. Light redirecting surface 119 redirects the light ray 107 primarily by total internal reflection (TIR) and through light output surface 137. In some aspects, the light redirecting surface 119 may be configured to receive a light ray 107 from the at least one optical fiber 115 along a direction of longitudinal axis LI and redirect the received light ray 107 along a different direction as shown. In some embodiments, the light redirecting surface 119 may be configured to change the direction of the light ray 107 received from the optical fiber 115 by at least 45 degrees, or at least 60 degrees, or, in some cases, about 90 degrees.

[0032] FIG. 4A show a schematic cross-sectional view of a connector assembly 100 where ferrules 110, 110' are coupled to each other such that mating surfaces 109, 109' are adjacent each other, and light output surface 137of ferrule 110 is proximate to and facing the light output surface 137' of ferrule 100'. In some embodiments, ferrules 110, 110' are hermaphroditic coupling units, which can be attached to each other. However, it is within the scope of the present disclosure that alternate coupling methods for ferrules 110, 110' can be used such as fasteners, couplers, etc. The connector assembly 100 is configured so that light exiting the optical fiber 115 enters the second optical fiber 115' after propagating through the light redirecting surfaces 119, 119' of the ferrules 110, 110', respectively.

[0033] FIG. 4B shows a perspective schematic view of light paths through the connector assembly 100 of FIG. 4A, according to one aspect of the disclosure. In FIG. 4B, the optical fiber 115 emits light ray 107, which is reflected from light redirecting surface 119, through first output surface 137, and enters light redirecting member 119' through output surface 137' as light ray 107'. Light ray 107' is then reflected from light redirecting surface 119' as input light that enters optical fiber 115'.

[0034] As mentioned previously, optical fibers 115 are inserted into the fiber attachment area 113. In particular, optical fibers 115 are inserted into the fiber guide elements 121 as part of the connectorization process for the optical fibers 115. Prior to insertion of the optical fibers 115 into the ferrule 110, the optical fibers 115 are laser processed. Optical fibers 115 are laser cleaved by techniques known in the art. In some embodiments, optical fibers 115 are first laserAttorney Docket No.: HI24-110PCT cleaved at an angle a (FIG. 3) relative to vertical axis L2 that is perpendicular to a longitudinal axis L2 of optical fiber 115. In some embodiments, the angle a ranges between about 5° and about 10° relative to the vertical axis L2 that is perpendicular to a longitudinal axis LI of the optical fiber. In some embodiments, the angle a is about 8° relative to the vertical axis L2 that is perpendicular to a longitudinal axis LI of the optical fiber. After laser cleaving, an end face 131 of the optical fiber 115 is laser treated such the end face 131 is rounded (FIG. 6A). In some embodiments, end face 131 has a radius of curvature ranging between about 1 microns and about 50 microns. In addition, the rounded end face 131 includes rounded edges 133 (FIG. 6A) which enable flexibility in insertion of the optical fiber 115 within fiber guide elements 121 (FIG. 6A) as discussed in greater detail herein. Moreover, the rounded end face 131 enables a core 135 to extend beyond the rounded edges 133 and beyond the stop 127 into the neck section 125 as discussed in greater detail herein. In some embodiments, the laser treatment steps are completed by a CO2 laser. However, it is within the scope of the present disclosure that alternate suitable lasers may be used such as mid-IR laser, ultraviolet laser, etc.

[0035] In some embodiments, a plurality of optical fibers 115 (e.g., a ribbon of optical fibers 115) may be laser cleaved and laser processed. When laser cleaving and laser processing the plurality of optical fibers 115, the end faces 131 are substantially coplanar with each other. In some embodiments, the end faces 131 are substantially coplanar within a range of about 1° of each other.

[0036] After optical fibers 115 have been laser cleaved and / or laser processed, optical fibers 115 are inserted into ferrule 110. In particular, optical fibers 115 are inserted into attachment area 113. As shown in FIG. 5A, optical fibers 115 are inserted at an angle R relative to a longitudinal axis L3 of ferrule 110. In some embodiments, angle R ranges between about 5° and about 20° relative to longitudinal axis L3 of the ferrule 110. By inserting optical fiber(s) 115 at angle R, optical fibers 115 are properly seated and positioned within fiber guide elements 121. Once inserted into the ferrule 110, optical fibers 115 are advanced through fiber guide elements 121 along direction Al as shown in FIG. 5B. In particular, in some embodiments, optical fibers 115 are advanced through fiber guide elements 121 until the edges 133 reach the stop 127. In some embodiments, optical fibers 115 are inserted into the fiber guide elements 121 and upon insertion, the positioning of optical fibers 115 are adjusted within the fiber guide elements 121 relative to the light input surface 129. Stated another way, once optical fibersAttorney Docket No.: HI24-110PCT115 are inserted into fiber guide elements 121, optical fibers 115 can be moved along directions Al or A2 (FIG. 6B) to position optical fibers 115 within ferrule 110.

[0037] As mentioned previously, in some embodiments, optical fibers 115 are inserted into fiber guide elements 121 and advanced along fiber guide elements 121 until edges 133 reach stop 127. In this embodiment, end faces 131 of optical fibers 115 extend into the neck section 125 of fiber guide elements 121 as shown in FIG. 6A. In some other embodiments, end faces 131 of optical fibers 115 are positioned within the guide section 123 distal to the stop 127 and neck section 125. In this configuration and as shown in FIG. 6A, core 135 extends beyond the stop 127 such that distance DI between the core 135 and the light input surface 129 is smaller than the distance D2 of conventional optical fibers 115 as illustrated in dashed lines in FIG. 6A (and as shown in FIG. 6B) where the end face 131 does not extend beyond stop 127 (i.e., distance D2 is the distance from the light input surface 129 to stop 127). In some embodiments, distance DI ranges between about 70 microns and about 90 microns. In some embodiments, distance D2 is about 80 microns. In some embodiments, where a plurality of optical fibers 115 are landed into respective fiber guide elements 121, distance DI can vary among the plurality of optical fibers 115 within a range from about 1 microns to about 10 microns. In some embodiments, where a plurality of optical fibers 115 are landed into respective fiber guide elements 121, distance DI can vary among the plurality of optical fibers 115 within a range from about 5 microns to about 10 microns.

[0038] With continued reference to FIG. 6A, a distance D3 is shown. Distance D3 represents a differential distance between distance D2 (as shown in FIG. 6B and represented by the dashed optical fiber 115 shown in FIG. 6A) and distance DI. That is, distance D3 is the differential distance D2-D1. As mentioned previously, distance D2 is the distance from the light input surface 129 to stop 127. The positioning of the optical fiber 115 can affect distance DI and in turn, distance D3 where in configurations where core 135 does not extend beyond stop 127 and into the neck section 125, distance D3 has a negative value. In some embodiments, distance D3 ranges from about -10 microns to about 10 microns.

[0039] By varying distance DI, the optical fiber 115 can be positioned within the fiber guide element 121 such that the focal point of the light emitted through the optical fiber 115 and reflected by light redirecting surface 119 can be optimized within optical connector 100, which in turn, optimizes the connectivity of the optical connector 100.Attorney Docket No.: HI24-110PCT

[0040] One advantage of inserting the optical fibers 115 into ferrule 110 after laser treatment as described above is that skiving within the fiber guide elements 121 is eliminated. When inserting optical fibers 115 that are not laser treated or that do not have the rounded end face 131 and / or rounded edges 133, there can be physical contact between the non-rounded (sharper) edges of optical fiber 115 and the fiber guide elements 121 of the ferrule 110 during the insertion process. The physical contact between the fiber guide elements 121 and the optical fiber 115 creates a skiving event in which debris in the form of small pieces of ferrule 110 can end up on the end face 131 of optical fiber 115. This can negatively affect the connectivity of the optical fiber 115 in ferrule 110 and can slow the speed of installation of optical fibers 115 due to the concern of potential skiving. Moreover, skiving can also require that installation of optical fibers 115 within fiber guide elements 121 occur in a single direction (Al) to mitigate the chance of any ferrule material contacting the end face 131 of optical fiber 115. By contrast, in the context of the present disclosure, because of the rounded edges 133 of optical fibers 115, insertion of the optical fibers 115 into fiber guide elements 121 (at angle R) does not promote skiving and does promotes greater installation speed of optical fibers 115 within ferrule 110. Furthermore, for the same reason, the optical fibers 115 can be inserted into and moved within fiber guide elements 121 along directions Al or A2 as shown in FIG. 5B. That is, optical fibers 115 can move in directions Al or A2 along longitudinal axis L3 of ferrule 110 due to the rounded edges 133 of optical fiber 110.

[0041] As such, positioning of the optical fibers 115 within fiber guide elements 121 can be variable among the optical fibers 115. This flexibility in optical fiber positioning enables for better connectivity performance as each optical fiber 115 can be tuned within the ferrule 110 to optimize performance and minimize insertion losses, etc.

[0042] There are many other alternatives and variations that will be appreciated by persons skilled in optical connectivity without departing from the spirit or scope of this disclosure. For at least this reason, the invention should be construed to include everything within the scope of the appended claims and their equivalents.

Claims

Attorney Docket No.: HI24-110PCTWhat is claimed is:

1. An optical connector assembly comprising: a ferrule comprising: a fiber guide element comprising a guide section and a neck section that extends from the guide section and that has a diameter that is less than a diameter of the guide section; wherein a stop is defined at an interface of the guide section and the neck section; and a light input surface adjacent the neck section of the fiber guide element; an optical fiber positioned in the fiber guide element of the ferrule, the optical fiber having a rounded end face extending into the neck section beyond the stop.

2. The optical connector assembly of claim 1, wherein the optical fiber end face has a radius of curvature ranging between about 1 micron and about 50 microns.

3. The optical connector assembly claim 1 or claim 2, wherein the optical fiber end face is spaced from the light input surface of the fiber guide element by a distance D3 ranging between about -10 microns and about 10 microns relative to the stop.

4. The optical connector assembly of any of claims 1-3, wherein the optical fiber comprises a core that is positioned beyond the stop of the fiber guide element.

5. The optical connector assembly of any of claims 1-4, wherein the optical fiber is inserted into the ferrule at an angle ranging between about 5° and about 20° relative to an axis of the ferrule.

6. The optical connector assembly of any of claims 1-5, wherein the fiber guide elements are V-grooves.

7. An optical connector assembly, comprising: a ferrule including a plurality of fiber guide elements and a light coupling portion adjacent the plurality of fiber guide elements, wherein:Attorney Docket No.: HI24-110PCT each fiber guide element of the plurality of fiber guide elements includes a guide section and a neck section that extends from the guide section and that has a smaller width than the guide section, a stop defined in each of the fiber guide elements at an interface of the guide section and the neck section, and the light coupling portion includes a light input surface facing the plurality of fiber guide elements; and a plurality of optical fibers each positioned in a respective fiber guide element of the plurality of fiber guide elements, wherein: each optical fiber of the plurality of optical fibers includes a rounded end face that extends into the neck section of the associated fiber guide element and that is spaced from the light input surface, at least one optical fiber of the plurality of optical fibers does not contact the stop of the associated fiber guide element, and at least one optical fiber of the plurality of optical fibers contacts the stop of the associated fiber guide element.

8. The optical connector assembly of claim 7, wherein each optical fiber of the plurality of optical fibers is positioned so that the rounded end face is spaced from the light input surface by a respective gap distance, and wherein the respective gap distances are within a range of about 1 microns and about 10 microns of each other.

9. The optical connector assembly of claim 7 or claim 8, wherein each optical fiber of the plurality of optical fibers is positioned so that the rounded end face is spaced from the light input surface by a respective gap distance, and wherein the respective gap distances are within a range of about 5 microns and about 10 microns of each other.

10. The optical connector assembly any of claims 7-9, wherein the rounded end faces are spaced from the light input surface by a distance D3 ranging between about -10 microns and about 10 microns relative to the stop.Attorney Docket No.: HI24-110PCT11. The optical connector assembly of any of claims 7-10, wherein the fiber guide elements are V-grooves.

12. A method of processing an optical fiber for insertion into an optical connector that comprises a ferrule having a fiber guide element comprising: a guide section and a neck section that has a diameter that is less than a diameter of the guide section; wherein the neck section extends from a stop to a lens at an end of the fiber guide element, wherein the stop is at an interface of the guide section and the neck section, the method comprising: laser cleaving the optical fiber; laser processing an end face of the optical fiber, wherein the optical fiber has a rounded end face; inserting the optical fiber into the fiber guide element of the optical connector, wherein the rounded end face extends into the neck section beyond the stop.

13. The method of claim 12, wherein the optical fiber end face has a radius of curvature ranging between about 1 micron and about 50 microns.

14. The method of claim 12 or claim 13, wherein the optical fiber end face is spaced from the light input surface of the fiber guide element by a distance D3 ranging between about -10 microns and about 10 microns relative to the stop.

15. The method of any of claims 12-14, wherein the optical fiber comprises a core that is positioned beyond the stop of the ferrule.

16. The method of any of claims 12-15, wherein the optical fiber is inserted into the ferrule at an angle ranging between about 5° and about 20°relative to an axis of the ferrule.

17. The method of any of claims 12-16, wherein the optical fiber is laser cleaved prior to insertion into the ferrule, wherein the optical fiber is cleaved at an angle of about 8° relative to a longitudinal axis of the optical fiber.

18. The method of any of claims 12-17, wherein the fiber guide elements are V-grooves.

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