High precision 9.6 µm CO(2) laser end-face processing of optical fibres.

Reproducible, precise cleaving of optical fibres is of great importance to the fibre laser and telecommunications industries. We present a novel approach to the end-face processing of optical fibres using a 9.6 µm CO₂ laser to produce flat, smooth and symmetric fibre end-face profiles with no rounding or melting at the edges of the fibre. As a demonstration, precision cleaving of a 400 µm diameter optical fibre is reported. For this fibre a topographical profile height of <400 nm (0.06°) and a reproducibility better than 200 nm (0.03°) was achieved. To the best of our knowledge this is the first demonstration of a CO₂ process that has generated a fibre end-face topography substantially smaller than a typical mechanical cleave. Highlighting the flexibility of this system, we have also demonstrated the generation of near arbitrary fiber end-face profiles such as discrete phase steps and non-spherical surface profiles.