Fiber Optic Concentric Stepped Ferrule

RC Integrated Systems LLC (RISL) proposes to develop a Fiber Optic Concentric Stepped (FOCS) Ferrule that can self-align the core of an optical fiber with the center of a lens of different outer diameter. Through use of a novel commercial off-the-shelf (COTS) materials and unique processing steps, the ferrules will meet all the Navy specifications including overall length of 10.00+.10 mm with a diameter of 1.58600005 mm, the larger cavity length of 4.0+0/-.2 mm with a diameter of 1.00+.03/-.00 mm, the smaller cavity diameter of 0.1255+0.001/-0.000 mm, and both cavities concentric to the outer diameter of the ferrule within 0.001 mm. The FOCS ferrule material has better performance in hardness and wear-resistance than zirconia ceramic. Use of low cost COTS materials, each ferrule will cost less than $40. In Phase I, RISL will develop the ferrule fabrication process and fabricate several ferrules for single mode fiber optic cable jumpers and demonstrate the FOCS feasibility. In Phase II, RISL will improve the design and process and fabricate at least 12 FOCS prototypes. RISL will measure the FOCS ferrules for accuracy and repeatability when tested for insertion loss within a range of optical fibers (e.g. 9/125 um, 50/125 um, 62.5/125 um).