Direct write of photonics using a filament-fed laser-heated process

Additive Manufacturing (AM) of low-profile 2.5D glass structures is demonstrated using a fiber-fed laser-heated process. In this process, glass single mode optical fibers with diameters 90-125 μm are fed into the intersection of a workpiece and CO2 laser beam. The workpiece is positioned by a four-axis CNC stage. Issues unique to the process are discussed, including the thermal breakdown of the glass and index inhomogeneity. Scanning electron microscopy reveals that the core/cladding structure of the fiber remains intact during printing and can be used to guide light for photonic applications.