Single-mode, multi-fiber expanded-beam connectors (EBCs) were fabricated based on a two-step process using coreless glass fibers and two-photon polymerization (TTP) 3D printing technique. First, coreless glass fibers were spliced onto a single-mode fiber ribbon and then precisely laser-cleaved to the ideal length. A micro-lens array was directly laser printed onto the coreless fiber extensions using the TPP technique to create the expanded, collimated output beam. Coupling loss measurements at 1310 nm between two 3D-printed EBCs matched the results of simulations. The high spatial resolution of the TPP technique avoids cumbersome active alignment procedures, and thus enables low-cost, high-throughput optical connectivity solutions.
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