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This paper presents the hot-embossing replication of self-centering fiber alignment structures for highprecision, single-mode optical fiber connectors. To this end, a metal mold insert was fabricated by electroforming a polymer prototype patterned by means of deep proton writing (DPW). To achieve through-hole structures, we developed a postembossing process step to remove the residual layer inherently present in hot-embossed structures. The geometrical characteristics of the hot-embossed replicas are compared, before and after removal of the residual layer, with the DPW prototypes. Initial measurements on the optical performance of the replicas are performed. The successful replication of these components paves the way toward low-cost mass replication of DPW-fabricated prototypes in a variety of high-tech plastics. [ABSTRACT FROM AUTHOR]

To boost the deployment of fiber-to-the-home networks in order to meet the ever-increasing demand for bandwidth, there is a strong need for single-mode fiber (SMF) connectors which combine low insertion loss with field installability. Shifting from ferrule-based to ferruleless connectors can reduce average insertion losses appreciably and minimize modal noise interference. We propose a ferruleless connector and adaptor in which physical contact between two inline fibers is ensured by at least one fiber being in a buckled state. To this end, we design a buckling cavity in which the SMF can buckle in a controlled way to ensure good optical performance as well as mechanical stability. This design is based on both mechanical and optical considerations. Finite element analysis suggests that mechanically a minimal buckling cavity length of 17 mm is required, while the height of the cavity should be chosen such that the buckled SMF is not mechanically confined to ensure buckling in a first-order mode. The optical bending loss in the buckled SMF is calculated using a fully vectorial mode solver, showing that aminimal buckling cavity length of 20 mm is necessary to keep the excess optical loss from bending below 0.1 dB. Both our optical and mechanical simulation results are experimentally verified. [ABSTRACT FROM AUTHOR]