Multi-Material Hybrid Additive Manufactured Flexible Photonic Substrate Bend Fatigue Test

Published: 20 September 2021| Version 1 | DOI: 10.17632/c8sscfb45d.1
Roger Tipton,


Manufacturing of an optical fiber interconnect device on a flexible substrate and procedure to evaluate the fatigue optical loss of a flexible optical fiber interconnect devices.


Steps to reproduce

Abstract Manufacturing of an optical fiber interconnect on a flexible substrate Materials PMMA - Treed  Kapton Film-125 micron  Kapton Tape - 50 micron UV Optical Adhesive, Norland 1369, 2100 cps  Acetone  ABS Filament  Equipment nScrypt 3Dn Desktop Printer UV Curing Lamp - BLAK-Ray Long Wave Ultraviolet Lamp, Model8 100 AP/R 304 Stainless Steel Sheet - 5 mm thick Procedure List protocol steps.   Step #1: Dissolve 5 g of ABS Filament into 50 mL of Acetone.   Step #2: Place stainless steel sheet on  automation bed.   Step #3: Load Kapton film onto stainless sheet and fix down with Kapton tape.   Step #4: Processing Parameters for manufacturing of an optical fiber by direct print additive manufacturing Process Parameter Value Micro-dispensing volume - 10 cc Micro-dispensing pressure - 6 psi UV curing time - 7 minutes UV wavelength  - 365 nm UV curing power - 21,700 mW/cm3 FDM nozzle diameter - 50-micron FDM nozzle temp  - 260 C FDM nozzle speed - 0.04 mm/s FDM nozzle traverse speed - 14 mm/s FDM bed temperature - 90 C Laser wavelength - 355 nm Laser power - 1.5 mW Laser repetition rate - 50 kHz Laser traverse speed - 50 mm/s Laser passes - 2     Step #4: Micro-Dispense optical adhesive cladding material   Step #5: UV cure the optical adhesive cladding material.   Step #6: Micro-dispense the ABS adhesive on both the starting and ending locations of the FDM filament on the flexible substrate on either side of the cladding.   Step #7: FDM print the PMMA from the ABS adhesive on the start of the flexible substrate so that it is fixed and then extrude through the cladding material and pause so that it is fixed to the other end of the cladding material on the ABS adhesive.   Step #8: Use the laser to ablate the ends of the fibers off so that the end facets are smooth and ready to be connected to optical components . Abstract Procedure to evaluate the fatigue optical loss of a flexible fiber  Equipment Melles Griot 05-LHR-911 laser at 632.8 nm wavelength 2 mirrors Beam splitter CCD Camera Pinhole LWD M SPLAN50 0.60 infinity / f=180 objective lens 3 axis stage  rotational stage Thorlabs USB Power Meter PM16-120 Bent fiber assembly for with stage mount Procedure List protocol steps.   Step #1:Load flexible optical fiber assembly into fixture and secure end  so that fiber can be connected to laser and output of laser is aligned with pinhole and then the power meter.   Step #2: Align end face to laser with 4 stages and CCD camera.  Adjusts may need to be made to maximize output power to optimize alignment.    Step #3: Record power measurement in unbent state.   Step #4: Bend the fiber with fixture to 90 degrees.  Move the pin hole and power meter to new exit position and take power reading and record   Step #5: Repeat for 1000 cycles and record the power reading in the unbent state every 50 cycles


Three Dimensional Printing, Optical Fiber Sensing