Ink-jet printing of collimating microlenses onto optical fibers

Collimating microlenses are "printed" from optical polymeric materials on the ends of optical fibers using ink-jet technology. In one embodiment the optical fibers are inserted into a collet, a stand-off distance from the open upper end of the collet. The open upper end is filled with optical fluid and a microlens is formed thereon to collimate light exiting the fiber through the microlens. In another embodiment optical fibers from a "ribbon" are separated and installed into a ferrule having multiple openings therethrough. In the same manner as in the collet embodiment, the ferrule openings serve as a mold for the lens formation with the end of the fiber being located at the focal distance of the lenslet formed in an on the ferrule. A non-wetting coating can serve to control spreading of the fluid optical material and allow lens radius control as well. The microlenses are hardened after formation.