Air-structured optical fiber drawn from a 3D-printed preform

4D Optical fibers based on shape-memory polymers

Adaptative objects based on shape-memory materials are expected to significantly impact numerous technological sectors including optics and photonics. In this work, we demonstrate the manufacturing of shape-memory optical fibers from the thermal stretching of additively manufactured preforms. First, we show how standard commercially-available thermoplastics can be used to produce long continuously-structured microfilaments with shape-memory abilities. Shape recovery as well as programmability performances of such elongated objects are assessed. Next, we open the way for light-guiding multicomponent fiber architectures that are able to switch from temporary configurations back to user-defined programmed shapes. In particular, we show that distinct designs of fabricated optical fibers can maintain efficient light transmission upon completion of multiple temperature-triggered bending/straightening cycles. Such fibers are also programmed into more complex shapes including coils or near 180 ° curvatures for delivering laser light around obstacles. Finally, a shape-memory exposed-core fiber is employed in fiber evanescent wave spectroscopy experiments to optimize the performance of the sensing scheme. We strongly expect that such actuatable fibers with light-guiding abilities will trigger exciting progress of unprecedented smart devices in the areas of photonics, electronics, or robotics.

Towards a Procedure-Optimised Steerable Catheter for Deep-Seated Neurosurgery

In recent years, steerable needles have attracted significant interest in relation to minimally invasive surgery (MIS). Specifically, the flexible, programmable bevel-tip needle (PBN) concept was successfully demonstrated in vivo in an evaluation of the feasibility of convection-enhanced delivery (CED) for chemotherapeutics within the ovine model with a 2.5 mm PBN prototype. However, further size reductions are necessary for other diagnostic and therapeutic procedures and drug delivery operations involving deep-seated tissue structures. Since PBNs have a complex cross-section geometry, standard production methods, such as extrusion, fail, as the outer diameter is reduced further. This paper presents our first attempt to demonstrate a new manufacturing method for PBNs that employs thermal drawing technology. Experimental characterisation tests were performed for the 2.5 mm PBN and the new 1.3 mm thermally drawn (TD) PBN prototype described here. The results show that thermal drawing presents a significant advantage in miniaturising complex needle structures. However, the steering behaviour was affected due to the choice of material in this first attempt, a limitation which will be addressed in future work.

Optical fiber with homogeneous material by side-array cladding

Optical fibers are the core elements for various fiber-optic applications in communication, lasers, sensors, tweezers, quantum optics, and bio-photonics. Current optical fibers are based on a core-cladding structure with different refractive indices and are mainly fabricated using the stack-draw method. However, such a traditional fabrication method limits the realization of fibers with various advanced optical materials, thereby restricting the utilization of excellent optical properties offered by these materials. In this study, a novel structure for side-array cladding by laser drilling on the side of the fiber with homogeneous material is proposed. Accordingly, the confinement loss, mode characteristics, birefringence, and dispersion of the side-array cladding fiber are investigated based on the numerical simulation performed via the finite element method. Subsequently, an optimal fiber structure is obtained by taking the crystal material as an example. Essentially, our proposed side-array cladding fiber can eliminate the mismatch problem of core-cladding materials in the current stack-draw fabrication method. Potentially, the proposed approach can serve as a standard design and fabrication method of optical fibers with homogeneous material, by utilizing the rapid development of laser processing. In other words, a large number of advanced optical materials can be fabricated into optical fibers with the proposed technique, thus maximizing their technical advantages for different applications.

Optical couplers and step-index fibers fabricated using FDM 3D printers

Step-index optical fiber preforms are manufactured and drawn into fibers using low-cost consumer-grade fused deposition modeling (FDM) 3D printers with no other specialist tooling. The fibers are fabricated from polyethylene terephthalate glycol (PETG) cladding with an acrylonitrile buatadiene styrene (ABS) core, resulting in V < 2.4 after drawing. The fibers are measured to have a loss of α ≈ 0.78 dB/cm, which matches previous polymer fibers manufactured using draw towers. The printing of multimode optical couplers with reliable 50:50 split ratios is also demonstrated. This work points toward the fabrication of useful and bespoke optical devices with low-cost 3D printers.

Infinity additive manufacturing of continuous microstructured fiber links for THz communications

In this work, a novel infinity 3D printing technique is explored to fabricate continuous few-meter-long low-loss near-zero dispersion suspended-core polypropylene fibers for application in terahertz (THz) communications. Particular attention is paid to process parameter optimization for 3D printing with low-loss polypropylene plastic. Three microstructured THz fibers were 3D printed using the standard and infinity 3D printers, and an in-depth theoretical and experimental comparison between the fibers was carried out. Transmission losses (by power) of 4.79 dB/m, 17.34 dB/m, and 11.13 dB/m are experimentally demonstrated for the three fibers operating at 128 GHz. Signal transmission with bit error rate (BER) far below the forward error correction limit (10^–3) for the corresponding three fiber types of lengths of 2 m, 0.75 m, and 1.6 m are observed, and an error-free transmission is realized at the bit rates up to 5.2 Gbps. THz imaging of the fiber near-field is used to visualize modal distributions and study optimal fiber excitation conditions. The ability to shield the fundamental mode from the environment, mechanical robustness, and ease of handling of thus developed effectively single-mode high optical performance fibers make them excellent candidates for upcoming fiber-assisted THz communications. Additionally, novel fused deposition modeling (FDM)-based infinity printing technique allows continuous fabrication of unlimited in length fibers of complex transverse geometries using advanced thermoplastic composites, which, in our opinion, is poised to become a key fabrication technique for advanced terahertz fiber manufacturing.

Low-Cost 3D Printer Drawn Optical Microfibers for Smartphone Colorimetric Detection

A fused deposition modeling (FDM) 3D printer extruder was utilized as a micro-furnace draw tower for the direct fabrication of low-cost optical fibers. An air-clad multimode microfiber was drawn from optically transparent polyethylene terephthalate glycol (PETG) filament. A custom-made spooling collection allows for an automatic variation of fiber diameter between ϕ ∼ 72 to 397 μm by tuning the drawing speed. Microstructure imaging as well as the 3D beam profiling of the transmitted beam in the orthogonal axes was used to show good quality, functioning microfiber fabrication with uniform diameter and identical beam profiles for orthogonal axes. The drawn microfiber was used to demonstrate budget smartphone colorimetric-based absorption measurement to detect the degree of adulteration of olive oils with soybean oil.

Anti-Reflection Coatings on 3D-Printed Components

The use of anti-reflection coatings on 3D-printed components to reduce both Fresnel reflections and scattering is explored. Two similar photo-initiated acrylic commercial material structures, known as Standard Clear (SC: T~60% @ λ = 800 nm) and VeroClear (VC: T~90% @ λ = 800 nm), used specifically for optical components, are examined. The refractive indices for slab samples~(5 × 5 × 0.7) cm are measured at λ = 650 nm and averaged over the slab area: n(SC)~(1.49 ± 0.04) and n(VC)~(1.42 ± 0.03). Within experimental error, novel Shore D mapping is used to show hardness distribution across the surface flats, with VC slightly harder than SC, where VC = 85.9 ± 0.3 and SC = 84.4 ± 1.3, indicating uniform hardness. A TiO2/MgF2 anti-reflection twin-layer coating is deposited onto one side of an unpolished SC slab and binds well, passing standard peeling and humidity tests. Shore hardness increases to SCCOATED = 87.5 ± 1.5. It is found to reduce the measured Fresnel reflection and surface scatter by~65% without requiring major polishing, paving the way for lower-cost high-quality optics. The demonstration of successful anti-reflection coatings will benefit all 3D-printed component finishes, permitting viable film deposition more broadly.

A Cross-Disciplinary View of Testing and Bioinformatic Analysis of SARS-CoV-2 and Other Human Respiratory Viruses in Pandemic Settings

The SARS-Coronavirus-2 (SARS-CoV-2) infectious disease, COVID-19, has spread rapidly, resulting in a global pandemic with significant mortality. The combination of early diagnosis via rapid screening, contact tracing, social distancing and quarantine has helped to control the pandemic. The absence of real time response and diagnosis is a crucial technology shortfall and is a key reason why current contact tracing methods are inadequate to control spread. In contrast, current information technology combined with a new generation of near-real time tests offers consumer-engaged smartphone-based "lab-in-a-phone" internet-of-things (IoT) connected devices that provide increased pandemic monitoring. This review brings together key aspects required to create an entire global diagnostic ecosystem. Cross-disciplinary understanding and integration of both mechanisms and technologies for effective detection, incidence mapping and disease containment in near real-time is summarized. Available measures to monitor and/or sterilize surfaces, next-generation laboratory and smartphone-based diagnostic approaches can be brought together and networked for instant global monitoring that informs Public Health policy. Cloud-based analysis enabling real-time mapping will enable future pandemic control, drive the suppression and elimination of disease spread, saving millions of lives globally. A new paradigm is introduced - scaled and multiple diagnostics for mapping and spreading of a pandemic rather than traditional accumulation of individual measurements. This can do away with the need for ultra-precise and ultra-accurate analysis by taking mass measurements that can relax tolerances and build resilience through networked analytics and informatics, the basis for novel swarm diagnostics. These include addressing ethical standards, local, national and international collaborative engagement, multidisciplinary and analytical measurements and standards, and data handling and storage protocols.

Biocompatible and Biodegradable Polymer Optical Fiber for Biomedical Application: A Review

This article discusses recent advances in biocompatible and biodegradable polymer optical fiber (POF) for medical applications. First, the POF material and its optical properties are summarized. Then, several common optical fiber fabrication methods are thoroughly discussed. Following that, clinical applications of biocompatible and biodegradable POFs are discussed, including optogenetics, biosensing, drug delivery, and neural recording. Following that, biomedical applications expanded the specific functionalization of the material or fiber design. Different research or clinical applications necessitate the use of different equipment to achieve the desired results. Finally, the difficulty of implanting flexible fiber varies with its flexibility. We present our article in a clear and logical manner that will be useful to researchers seeking a broad perspective on the proposed topic. Overall, the content provides a comprehensive overview of biocompatible and biodegradable POFs, including previous breakthroughs, as well as recent advancements. Biodegradable optical fibers have numerous applications, opening up new avenues in biomedicine.

Fabrication Quality Assessment Based on the Coupling of a Dual-Core Microstructured Polymer Optical Fiber

In this paper we report on the theoretical analysis and fabrication of a dual-core microstructured polymer optical fiber (mPOF) and demonstrate how the coupling characteristics of a dual-core mPOF may be a key factor to assess the quality of the fabrication process. The coupling characteristics of this fiber have been tested and, for comparison purposes, simulations regarding the effects of inaccuracies during the manufacturing process were carried out to evaluate the fabrication quality. Results indicate that theoretical, simulation and experimental data are in good agreement, which highlights the uniformity of the microstructure along the fiber and the quality of its fabrication process. In fact, the manufactured mPOF reached a coupling efficiency up to 95.26%, which makes this mPOF appealing for applications in which highly efficient power couplers are required.

3D printing of glass by additive manufacturing techniques: a review

Additive manufacturing (AM), which is also known as three-dimensional (3D) printing, uses computer-aided design to build objects layer by layer. Here, we focus on the recent progress in the development of techniques for 3D printing of glass, an important optoelectronic material, including fused deposition modeling, selective laser sintering/melting, stereolithography (SLA) and direct ink writing. We compare these 3D printing methods and analyze their benefits and problems for the manufacturing of functional glass objects. In addition, we discuss the technological principles of 3D glass printing and applications of 3D printed glass objects. This review is finalized by a summary of the current achievements and perspectives for the future development of the 3D glass printing technique.

Challenges in the Fabrication of Biodegradable and Implantable Optical Fibers for Biomedical Applications

The limited penetration depth of visible light in biological tissues has encouraged researchers to develop novel implantable light-guiding devices. Optical fibers and waveguides that are made from biocompatible and biodegradable materials offer a straightforward but effective approach to overcome this issue. In the last decade, various optically transparent biomaterials, as well as different fabrication techniques, have been investigated for this purpose, and in view of obtaining fully fledged optical fibers. This article reviews the state-of-the-art in the development of biocompatible and biodegradable optical fibers. Whilst several reviews that focus on the chemical properties of the biomaterials from which these optical waveguides can be made have been published, a systematic review about the actual optical fibers made from these materials and the different fabrication processes is not available yet. This prompted us to investigate the essential properties of these biomaterials, in view of fabricating optical fibers, and in particular to look into the issues related to fabrication techniques, and also to discuss the challenges in the use and operation of these optical fibers. We close our review with a summary and an outline of the applications that may benefit from these novel optical waveguides.

A Highly Birefringent Photonic Crystal Fiber for Terahertz Spectroscopic Chemical Sensing

A photonic crystal fiber (PCF) with high relative sensitivity was designed and investigated for the detection of chemical analytes in the terahertz (THz) regime. To ease the complexity, an extremely simple cladding employing four struts is adopted, which forms a rectangular shaped core area for filling with analytes. Results of enormous simulations indicate that a minimum 87.8% relative chemical sensitivity with low confinement and effective material absorption losses can be obtained for any kind of analyte, e.g., HCN (1.26), water (1.33), ethanol (1.35), KCN (1.41), or cocaine (1.50), whose refractive index falls in the range of 1.2 to 1.5. Besides, the PCF can also achieve high birefringence (∼0.01), low and flat dispersion, a large effective modal area, and a large numerical aperture within the investigated frequency range from 0.5 to 1.5 THz. We believe that the proposed PCF can be applied to chemical sensing of liquid and THz systems requiring wide-band polarization-maintaining transmission and low attenuation.

Biomedical optical fibers

Optical fibers with the ability to propagate and transfer data via optical signals have been used for decades in medicine. Biomaterials featuring the properties of softness, biocompatibility, and biodegradability enable the introduction of optical fibers' uses in biomedical engineering applications such as medical implants and health monitoring systems. Here, we review the emerging medical and health-field applications of optical fibers, illustrating the new wave for the fabrication of implantable devices, wearable sensors, and photodetection and therapy setups. A glimpse of fabrication methods is also provided, with the introduction of 3D printing as an emerging fabrication technology. The use of artificial intelligence for solving issues such as data analysis and outcome prediction is also discussed, paving the way for the new optical treatments for human health.

A Novel Gold Film-Coated V-Shape Dual-Core Photonic Crystal Fiber Polarization Beam Splitter Covering the E + S + C + L + U Band

In this paper, a novel gold film-coated V-shape dual-core photonic crystal fiber (V-DC-PCF) polarization beam splitter (PBS) based on surface plasmon resonance effect is proposed. The coupling lengths of the X-polarization (X-pol) and Y-polarization (Y-pol) and the corresponding coupling length ratio of the proposed V-DC-PCF PBS without gold film and with gold film are compared. The fiber structure parameters and thickness of the gold film are optimized through investigating their effects on the coupling lengths and coupling length ratio. As the propagation length increases, the normalized output powers of the X-pol and Y-pol of the proposed V-DC-PCF PBS at the three wavelengths 1.610, 1.631, and 1.650 μm are demonstrated. The relationships between the extinction ratio (ER), insertion loss (IL) and wavelength for the three splitting lengths (SLs) 188, 185, and 182 μm are investigated. Finally, it is demonstrated that for the proposed V-DC-PCF PBS, the optimal SL is 188 μm, the ILs of the X-pol and Y-pol are less than 0.22 dB, and the splitting bandwidth (SB) can cover the E + S + C + L + U band. The proposed V-DC-PCF PBS has the ultra-short SL, ultra-wide SB, and ultra-low IL, so it is expected to have important applications in the laser, sensing, and dense wavelength division multiplexing systems.

Helical distributed feedback fiber Bragg gratings and rocking filters in a 3D printed preform-drawn fiber

Using induced UV attenuation across a twisted fiber asymmetric core drawn from a 3D printed preform, linear fiber Bragg gratings (FBGs) are produced on one side of the core. By removing the twist, a helical grating with a period matching the twist rate is produced. Balancing the rate with the polarization beat length in a form birefringent fiber allows the production of a combined rocking filter and FBG device with tunable properties. Direct observation of the fiber grating dispersion within the rocking filter rejection band is possible.

Magnetic Field-Assisted Stereolithography for Productions of Multimaterial Hierarchical Surface Structures

Natural organisms provide inspirations for various functional structures and surfaces with significant applications in multidisciplinary fields. These biological systems are generally composed of multiscale surface structures with high geometric complexity and a variety of materials, making it challenging to replicate their characteristics in engineering. This study presents a novel multiscale multimaterial 3D printing method, magnetic field-assisted stereolithography (M-SL), for fabricating hierarchical particle-polymer structures with surface features ranging from a few nanometers to millimeters or even centimeters. Taking inspiration from nature, this study describes the design and fabrication of a bioinspired multiscale hierarchical surface structure, which is characterized of microscale cones, nanoscale pores, and surface wrinkles at a few nanometers. To understand the fundamental physics underlying the hierarchical surface structure fabrication in the proposed M-SL process, the complexities among the M-SL process parameters, material parameters, and printed geometries are discussed. The accuracy of the developed printing method is investigated by comparing the printed geometries and digital designs. Effects of the printed hierarchical surface structure on hydrophobicity and cell viability were characterized and discussed. It was found that the highly hierarchical surface structure changed the polymer composite surface from hydrophilic (contact angle: ∼38°) to hydrophobic (∼146°). In addition, the hierarchical surface structure also created a better environment for cell attachment and growth, with 900% more living cells at 72 h after cell seeding, compared with cells on the nonstructured smooth surface. Local and selective cell seeding can also be enabled by the surface structure design. Experimental results validated the effectiveness of the M-SL 3D printing method on fabricating multimaterial functional objects with hierarchically structured surfaces for a wide spectrum of applications.

Induced neural stem cell differentiation on a drawn fiber scaffold-toward peripheral nerve regeneration

To achieve regeneration of long sections of damaged nerves, restoration methods such as direct suturing or autologous grafting can be inefficient. Solutions involving biohybrid implants, where neural stem cells are grown in vitro on an active support before implantation, have attracted attention. Using such an approach, combined with recent advancements in microfabrication technology, the chemical and physical environment of cells can be tailored in order to control their behaviors. Herein, a neural stem cell polycarbonate fiber scaffold, fabricated by 3D printing and thermal drawing, is presented. The combined effect of surface microstructure and chemical functionalization using poly-L-ornithine (PLO) and double-walled carbon nanotubes (DWCNTs) on the biocompatibility of the scaffold, induced differentiation of the neural stem cells (NSCs) and channeling of the neural cells was investigated. Upon treatment of the fiber scaffold with a suspension of DWCNTs in PLO (0.039 g l^-1) and without recombinants a high degree of differentiation of NSCs into neuronal cells was confirmed by using nestin, galactocerebroside and doublecortin immunoassays. These findings illuminate the potential use of this biohybrid approach for the realization of future nerve regenerative implants.

Ultra-simplified Single-Step Fabrication of Microstructured Optical Fiber

Manufacturing optical fibers with a microstructured cross-section relies on the production of a fiber preform in a multiple-stage procedure, and drawing of the preform to fiber. These processes encompass the use of several dedicated and sophisticated equipment, including a fiber drawing tower. Here we demonstrate the use of a commercial table-top low-cost filament extruder to produce optical fibers with complex microstructure in a single step - from the pellets of the optical material directly to the final fiber. The process does not include the use of an optical fiber drawing tower and is time, electrical power, and floor space efficient. Different fiber geometries (hexagonal-lattice solid core, suspended core and hollow core) were successfully fabricated and their geometries evaluated. Air guidance in a wavelength range where the fiber material is opaque was shown in the hollow core fiber.

Chirping fiber Bragg gratings within additively manufactured polymer packages

Fiber Bragg gratings are embedded within 3D printed polymer packages. Information about both induced and applied stresses, and operator error, can be determined from the observed spectral shifts and chirping. A novel way to produce packaged broadband gratings, with $\Delta {\lambda _{\rm BW}}\gt {7}\;{\rm nm/cm}$Δλ_BW>7nm/cm, is proposed and demonstrated.

Silica optical fiber drawn from 3D printed preforms

Silica optical fiber was drawn from a three-dimensional printed preform. Both single mode and multimode fibers are reported. The results demonstrate additive manufacturing of glass optical fibers and its potential to disrupt traditional optical fiber fabrication. It opens up fiber designs for novel applications hitherto not possible.

Harnessing Deep-Hole Drilling to Fabricate Air-Structured Polymer Optical Fibres

The performance of a precisely controlled drilling technique is critical in the fabrication process of microstructured polymer optical fibres. For the creation of a holey preform, adequate drilling bits with large length-to-diameter ratios provide the ability of machining preforms with complex structures and large lengths in a relatively short time. In this work, we analysed different drilling bits and techniques that can be employed for the creation of such preforms, and key parameters characterising the quality of the drilled holes, such as surface rugosity, diameter deviation, coaxiality and cylindricity were measured. For this purpose, based on theoretical simulations, four rings of air holes arranged in a hexagonal pattern were drilled in the preforms with different drill bits, and the experimental results for the above mentioned parameters have been presented. Additionally, optical power distribution of the fabricated microstructured polymer optical fibres was theoretically calculated and experimentally measured.

Suspended-Core Microstructured Polymer Optical Fibers and Potential Applications in Sensing

The study of the fabrication, material selection, and properties of microstructured polymer optical fibers (MPOFs) has long attracted great interest. This ever-increasing interest is due to their wide range of applications, mainly in sensing, including temperature, pressure, chemical, and biological species. This manuscript reviews the manufacturing of MPOFs, including the most recent single-step process involving extrusion from a modified 3D printer. MPOFs sensing applications are then discussed, with a stress on the benefit of using polymers.

Polymer Optical Fiber Sensors in Healthcare Applications: A Comprehensive Review

Advances in medicine and improvements in life quality has led to an increase in the life expectancy of the general population. An ageing world population have placed demands on the use of assistive technology and, in particular, towards novel healthcare devices and sensors. Besides the electromagnetic field immunity, polymer optical fiber (POF) sensors have additional advantages due to their material features such as high flexibility, lower Young’s modulus (enabling high sensitivity for mechanical parameters), higher elastic limits, and impact resistance. Such advantages are well-aligned with the instrumentation requirements of many healthcare devices and in movement analysis. Aiming at these advantages, this review paper presents the state-of-the-art developments of POF sensors for healthcare applications. A plethora of healthcare applications are discussed, which include movement analysis, physiological parameters monitoring, instrumented insoles, as well as instrumentation of healthcare robotic devices such as exoskeletons, smart walkers, actuators, prostheses, and orthosis. This review paper shows the feasibility of using POF sensors in healthcare applications and, due to the aforementioned advantages, it is possible to envisage a further widespread use of such sensors in this research field in the next few years.

Novel method for manufacturing optical fiber: extrusion and drawing of microstructured polymer optical fibers from a 3D printer

Microstructured polymer optical fibers (MPOFs) have long attracted great interest due to their wide range of applications in biological and chemical sensing. In this manuscript, we demonstrate a novel technique of manufacturing MPOF via a single-step procedure by means of a 3D printer. A suspended-core polymer optical fiber has been extruded and directly drawn from a micro-structured 3D printer nozzle by using an acrylonitrile butadiene styrene (ABS) polymer. Near-field imaging at the fiber facet performed at the wavelength λ~1550 nm clearly indicates guidance in the fiber core. The propagation loss has been experimentally demonstrated to be better than α = 1.1 dB/cm. This work points toward direct MPOFs manufacturing of varieties of materials and structures of optical fibers from 3D printers using a single manufacturing step.

Low-Cost Passive Sampling Device with Integrated Porous Membrane Produced Using Multimaterial 3D Printing

Multimaterial 3D printing facilitates the rapid production of complex devices with integrated materials of varying properties and functionality. Herein, multimaterial fused deposition modeling (MM-FDM) 3D printing was applied to the fabrication of low-cost passive sampler devices with integrated porous membranes. Using MM-FDM 3D printing, the device body was produced using black polylactic acid, with Poro-Lay Lay-Felt filament used for the printing of the integrated porous membranes (rubber-elastomeric polymer, porous after removal of a water-soluble poly(vinyl alcohol) component). The resulting device consisted of two interlocking circular frames, each containing the integrated membrane, which could be efficiently sealed together without the need for additional O-rings, and prevented loss of enclosed microparticulate sorbent. Scanning electron microscopy (SEM) analysis of the purified composite filament confirmed the porous properties of the material, an average pore size of ∼30 nm. The printed passive samplers with various membrane thicknesses, including 0.5, 1.0, and 1.5 mm, were evaluated for their ability to facilitate the extraction of atrazine as the model solute onto the internal sorbent, under standard conditions. Gas chromatography-mass spectrometry was used to determine the uptake of atrazine by the device from standard water samples and also to evaluate any chemical leaching from the printed materials. The sampler with 0.5 mm thick membrane showed the best performance with 87% depletion and a sampling rate of 0.19 Ld^-1 ( n = 3, % RSD = 0.59). The results obtained using these printed sampling devices with integrated membranes were in close agreement to devices fitted with a standard poly(ether sulfone) membrane.

Recent Progress in Biomimetic Additive Manufacturing Technology: From Materials to Functional Structures

Nature has developed high-performance materials and structures over millions of years of evolution and provides valuable sources of inspiration for the design of next-generation structural materials, given the variety of excellent mechanical, hydrodynamic, optical, and electrical properties. Biomimicry, by learning from nature's concepts and design principles, is driving a paradigm shift in modern materials science and technology. However, the complicated structural architectures in nature far exceed the capability of traditional design and fabrication technologies, which hinders the progress of biomimetic study and its usage in engineering systems. Additive manufacturing (three-dimensional (3D) printing) has created new opportunities for manipulating and mimicking the intrinsically multiscale, multimaterial, and multifunctional structures in nature. Here, an overview of recent developments in 3D printing of biomimetic reinforced mechanics, shape changing, and hydrodynamic structures, as well as optical and electrical devices is provided. The inspirations are from various creatures such as nacre, lobster claw, pine cone, flowers, octopus, butterfly wing, fly eye, etc., and various 3D-printing technologies are discussed. Future opportunities for the development of biomimetic 3D-printing technology to fabricate next-generation functional materials and structures in mechanical, electrical, optical, and biomedical engineering are also outlined.

3D printed fiber optic faceplates by custom controlled fused deposition modeling

A 3D printing technique for manufacturing air-clad coherent fiber optic faceplates is presented. The custom G-code programming is implemented on a fused deposition modeling (FDM) desktop printer to additively draw optical fibers using high-transparency thermoplastic filaments. The 3D printed faceplate consists of 20000 fibers and achieves spatial resolution 1.78 LP/mm. Transmission loss and crosstalk are characterized and compared among the faceplates printed from four kinds of transparent filaments as well as different faceplate thicknesses. The printing temperature is verified by testing the transmission of the faceplates printed under different temperatures. Compared with the conventional stack-and-draw fabrication, the FDM 3D printing technique simplifies the fabrication procedure. The ability to draw fibers with arbitrary organization, structure and overall shape provides additional degree of freedom to opto-mechanical design. Our results indicate a promising capability of 3D printing as the manufacturing technology for fiber optical devices.

Self-assembly three-dimensional optical devices: from microsphere to microlens array

We report rapid formation of three-dimensional micro optical devices by silica nanoparticle self-assembly in a face-centered cubic (fcc) structure. By controlling the hydrophobic interactions, the self-assembled products are fabricated into different morphologies, which include microsphere and hemisphere. These structures have specific applications in microsphere resonant cavities and microlens arrays. The whispering gallery mode of the formed microsphere is excited by the tapered fiber to demonstrate the optical characters of the microsphere. Moreover, the properties of the fabricated microlens and microlens array are tested through insertion in an imaging system. Ultimately, the optical devices with advanced functions are demonstrated by the secondary phase infiltrating into the interstitial space of silica nanoparticles. This report will open a new direction in manufacturing multifunctional and miniature optical devices by an ultrasimple self-assembly approach.

Mid-IR Hollow-core microstructured fiber drawn from a 3D printed PETG preform

Mid-infrared (mid-IR) optical fibers have long attracted great interest due to their wide range of applications in security, biology and chemical sensing. Traditionally, research was directed towards materials with low absorption in the mid-IR region, such as chalcogenides, which are difficult to manipulate and often contain highly toxic elements. In this paper, we demonstrate a Polyethylene Terephthalate Glycol (PETG) hollow-core fiber (HCF) with guiding properties in the mid-IR. Guiding is provided by the fiber geometry, as PETG exhibits a material attenuation 2 orders of magnitude larger than the HCF propagation loss. The structured plastic fiber preforms were fabricated using commercial 3D printing technology and then drawn using a conventional fiber drawing tower. The final PETG fiber outer diameter was 466 µm with a hollow-core diameter of 225 µm. Thermal imaging at the fiber facet performed within the wavelength range 3.5–5 µm clearly indicates air guidance in the fiber hollow-core.

Drawing optical fibers from three-dimensional printers

The temperature distribution within extrusion nozzles of three low-cost desktop 3D printers is characterized using fiber Bragg gratings (FBGs) to assess their compatibility as micro-furnaces for optical fiber and taper production. These profiles show remarkably consistent distributions suitable for direct drawing of optical fiber. As proof of principle, coreless optical fibers (φ=30  μm) made from fluorinated acrylonitrile butadiene styrene (ABS) and polyethylene terephthalate glycol (PETG) are drawn. Cutback measurements demonstrate propagation losses as low as α=0.26  dB/cm, which are comparable with standard optical fiber losses with some room for improvement. This work points toward direct optical fiber manufacture of any material from 3D printers.

Exciting surface plasmons on metal-coated multimode optical waveguides using skew rays

Multipoint surface plasmon resonance (SPR) excitation using a skew ray within a multimode plastic optical waveguide coated with gold, Au, is reported. The effect of skew rays on the performance of SPR has been studied both theoretically and experimentally. The approach also entails a novel method of measuring the SPR angle that is in agreement with theoretically predicted values.

Step-index optical fiber drawn from 3D printed preforms

Optical fiber is drawn from a dual-head 3D printer fabricated preform made of two optically transparent plastics with a high-index core (NA∼0.25, V>60). The asymmetry observed in the fiber arises from asymmetry in the 3D printing process. The highly multimode optical fiber has losses measured by cut-back as low as α∼0.44  dB/cm in the near IR.

Optical fiber smartphone spectrometer

An optical fiber-based smartphone spectrometer incorporating an endoscopic fiber bundle is demonstrated. The endoscope allows transmission of the smartphone camera LED light to a sample, removing complications from varying background illumination. The reflected spectra collected from a surface or interface is dispersed onto the camera CMOS using a reflecting diffraction grating. A spectral resolution as low as δλ∼2.0  nm over a bandwidth of Δλ∼250  nm is obtained using a slit width, ω_slit=0.7  mm. The instrument has vast potential in a number of industrial applications including agricultural produce analysis. Spectral analysis of apples shows straightforward measurement of the pigments anthocyanins, carotenoid, and chlorophyll, all of which decrease with increasing storage time.

3D printed long period gratings for optical fibers

We demonstrate a simple technique for implementing long period grating (LPG) structures by the use of a 3D printer. This Letter shows a way of manipulating the mode coupling within an optical fiber by applying stress through an external 3D printed periodic structure. Different LPG lengths and periods have been studied, as well as the effect of the applied stress on the coupling efficiency from the fundamental mode to cladding modes. The technique is very simple, highly flexible, affordable, and easy to implement without the need of altering the optical fiber. This Letter is part of a growing line of interest in the use of 3D printers for optical applications.