Axi-Stack: A method for manufacturing freeform air-silica optical fibre

We present a method with potential for fabricating freeform air-silica optical fibre preforms which is free from the stacking constraints associated with conventional stack-and-draw. The method, termed Axi-Stack, is enabled by the precision machining of short cross-sectional preform discs by ultrafast laser assisted etching; a laser-based microfabrication technique which facilitates near arbitrary shaping of the preform structure. Several preform discs are stacked axially and fused together via ultrafast laser welding to construct the preform, which can be drawn to fibre using conventional methods. To illustrate the Axi-Stack process, we detail the fabrication of a 30 cm long solid-core photonic crystal fibre preform with a square lattice of cladding holes and characterise fibre drawn from it.