Polymer Optical Fiber Tip Mass Production Etch Mechanism to Achieve CPC Shape for Improved Biosensor Performance

We report on a simple chemical etching method that enables nonlinear tapering of Polymer Optical Fiber (POF) tips to manufacture Compound Parabolic Concentrator (CPC) fiber tips. We show that, counter-intuitively, nonlinear tapering can be achieved by first etching the core and not the cladding. The etching mechanism is modelled and etched tips are characterized both geometrically and optically in a fluorescence glucose sensor chemistry. A Zemax model of the CPC tipped sensor predicts an optimal improvement in light capturing efficiency of a factor of 3.96 compared to the conventional sensor with a plane-cut fiber tip. A batch of eight CPC fiber tips has been manufactured by the chemical etching method. The batch average showed an increase of a factor of 3.16, which is only 20% less than the predicted value. The method is reproducible and can be up-scaled for mass production.