Abstract: An improved coating for optical fibers is described. The present invention is a dimensionally precise and uniform coating with low-porosity. The improved coating is applied via sputtering within a vacuum chamber. Environmental conditions are monitored within a cylindrical magnetron during sputtering. Sputtering is adjusted or temporarily ceased when environmental conditions approach a damage threshold. Sputtered particles within a plasma cloud are dimensionally similar and adhere to an optical fiber in a volume efficient arrangement forming a more precise, denser, and more adherent coating. Embodiments of the present invention provide improved pull strength by compressively constraining the optical fiber within the coating and by closing microcracks.

Abstract: An improved coating for optical fibers and a method for applying the improved coating are described. The present invention is a dimensionally precise and uniform coating with low-porosity. The improved coating is applied via sputtering within a vacuum chamber. Environmental conditions are monitored within a cylindrical magnetron during sputtering. Sputtering is adjusted or temporarily ceased when environmental conditions approach a damage threshold. Sputtered particles within a plasma cloud are dimensionally similar and adhere to an optical fiber in a volume efficient arrangement forming a more precise, denser, and more adherent coating. Embodiments of the present invention provide improved pull strength by compressively constraining the optical fiber within the coating and by closing microcracks.

Abstract: The present invention consists of a method and a structure formed by such method relating to optical fibers. Specifically, the invention consists of a chemical mill process for shaping the end of a fiber and thereby simultaneously forming both lens and precision mounting region. Also described is a self-aligning structure with integral lens. Both features improve light coupling. The lens focuses light energy entering and exiting the fiber. The precision mounting region facilitates alignment of fiber at couplings.