3D Printed Microstructures on Optical Fiber Ends
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Solution Overview
Problem
Current methods for producing microstructures on optical fibers are limited by the need for precise alignment and complex adjustment steps, as well as the challenges of handling and integrating micro-optical components with optical fibers, which are exacerbated by the small dimensions and low weight of these components.
Innovation Solution
A method involving the use of a 3D printer to align and expose photoresist on the axial end of an optical fiber, allowing for the direct formation of microstructures with submicrometer precision, eliminating the need for separate molds and simplifying the integration process by applying photoresist directly to the fiber end and using a 3D lithography system for polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional precision micro-injection molding or ultra-precision machining is used to manufacture micro-optical components, then manufacturing precision can be achieved, but device complexity and handling difficulty increase due to separate assembly and alignment steps
Solution Approach 1:
The patent merges the manufacturing of micro-optical components directly with the optical fiber by using 3D printing to fabricate structures on the fiber end face itself, eliminating the need for separate components and assembly steps. This combining approach resolves the contradiction by maintaining precision while removing complexity.
Solution Approach 2:
The optical fiber serves multiple functions: as the substrate for manufacturing, as the structural support, and as the optical transmission medium. The 3D printing process adds micro-optical functionality directly to the fiber, making the fiber a multi-functional component that eliminates separate micro-optical elements and their associated alignment complexity.
2Manufacturing precision
If micro-optical components are manufactured using conventional methods, then manufacturing precision can be achieved, but ease of manufacture decreases due to special tools and post-processing requirements
Solution Approach 1:
The optical fiber itself serves as the substrate and structural component, eliminating the need for separate molds, fixtures, and post-processing equipment. The 3D printing process directly modifies the fiber end face, making the fiber self-sufficient as both structure and optical element, thereby simplifying manufacturing while maintaining precision.
Solution Approach 2:
The patent replaces conventional mechanical manufacturing methods (injection molding, machining, EDM, milling, grinding) with 3D printing technology. This substitution eliminates the need for specialized mechanical tools and post-processing steps, simplifying the manufacturing process while achieving the required precision for micro-optical components.
3Volume of moving object
If micro-optical components are manufactured with small dimensions, then miniaturization is achieved, but ease of operation worsens due to handling difficulty and electrostatic effects
Solution Approach 1:
By merging the micro-optical component manufacturing directly onto the optical fiber, the patent creates an integrated structure where the fiber itself supports the micro-structures. This eliminates the need to handle separate micro-components, resolving the handling difficulty while maintaining miniaturization benefits.
4Manufacturing precision
If precise assembly and alignment of micro-optical components with optical fibers is performed, then manufacturing precision is maintained, but loss of time increases due to additional adjustment steps
Solution Approach 1:
The patent merges the micro-optical component fabrication directly with the optical fiber using 3D printing, eliminating the separate assembly and alignment steps. Since the structures are created directly on the fiber end face, precision is inherent to the manufacturing process rather than requiring subsequent alignment adjustments, thereby eliminating time loss.
Solution Approach 2:
The 3D printing process performs the alignment and positioning actions during the manufacturing phase itself, rather than requiring separate post-manufacturing alignment steps. The micro-structures are created in their final positions directly on the fiber, performing the alignment action preliminarily during fabrication and eliminating subsequent adjustment time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the precise and reproducible production of micro-optical components directly on optical fibers with resolutions below one micrometer, facilitating miniaturization and complex optical designs without the need for additional alignment steps or molds, thus simplifying handling and production.
Implementation Method 1
formation of at least one microstructure by exposing the photoresist with the aid of the 3D printer
Data Source
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Figure 3a~3f
AI summary
The invention relates to a method and a device for producing at least one microstructure (5) on an axial end (1a) of an optical fibre (1). The method comprises the following steps: - providing (S10) the optical fibre (1); - wetting (S20) the axial end (1a) of the optical fibre (1) with photoresist (2); - orienting (S30) the optical fibre (1) and a writing beam of a 3D printer with respect to one another; - forming (S40) the at least one microstructure (5) by exposing the photoresist (2) to light with the aid of the 3D printer.