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Optical fiber coupling plays a critical role in various fields, particularly when fibers are utilized in alignment stations. The efficiency of coupling is greatly influenced by the incident angles of the transmitting and receiving fibers. To enhance the coupling efficiency, one effective approach involves employing optical elements at the ends of one or both fibers. In this paper, we introduce a method for manufacturing lenses on optical fibers using a liquid polymer and strong electric fields to deform the liquid polymer into a defined shape. Our experimental setup includes cameras, linear axes, LEDs, electrodes, and a high voltage supply, enabling precise control of the deformation process. By applying an electrical field, we deform a liquid polymer droplet on the fiber tip, allowing us to create lenses of various shapes based on the electrode configuration. These lenses are fabricated using a UV-curable polymer which can be subsequently cured with UV light. We evaluate the quality and performance of the lensed fibers by reconstructing the 3D shape of the droplet and then utilizing raytracing. Furthermore, we present an innovative approach to calculate the electric field during in-situ deformation of the polymer droplet. This numerical method utilizes data and images obtained from the linear axes. By combining experimental observations with computational modeling, we gain valuable insights into the behavior and characteristics of the electric field. Our research offers a practical technique for manufacturing optical fibers with customized lenses and provides a comprehensive understanding of the electrical field dynamics involved. This approach has the potential to significantly improve coupling efficiency and advance the field of photonics.
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