We present a new technique for fabricating compliant mechanisms from stamped metal sheets. The concept works by providing thinned segments to allow rotation of flexural beams 90 deg about their long axis, effectively providing a flexure as wide as the sheet’s thickness. The method is demonstrated with the design and fabrication of a metal bistable mechanism for use as a threshold accelerometer. A new model based on elliptic integral solutions is presented for bistable mechanisms incorporating long, thin flexures. The resulting metal bistable mechanisms are tested for acceleration threshold sensing using a drop test and a vibration test. The mechanisms demonstrate very little variation due to stress relaxation or temperature effects. The force-displacement behavior of a mechanism is also measured. The mechanisms’ switching force is less than the designed value because of out-of-plane motion and dynamic effects.

We present a new type of fiber Bragg grating (FBG) in which we etch the grating into the flat surface of a D-shaped optical fiber. Instead of being written in the core of the fiber, as are standard FBGs, these surface-relief FBGs are placed in the cladding above the core. These gratings are a viable alternative to standard FBGs for sensing applications. We describe the fabrication process for etching Bragg gratings into the surface of D-fibers and demonstrate their performance as temperature sensors.

This paper provides a detailed analysis of electric field sensing using a slab-coupled optical fiber sensor (SCOS). This analysis explains that the best material for the slab waveguide is an inorganic material because of the low RF permittivity combined with the high electro-optic coefficient. The paper also describes the fabrication and testing of a SCOS using an AJL chromophore in amorphous polycarbonate. The high uniform polymer slab waveguide is fabricated using a hot embossing process to create a slab with a thickness of $50\text{\hspace{0.17em} μm}$. The fabricated polymer SCOS was characterized to have a resonance slope of $\mathrm{\Delta }P/\mathrm{\Delta }\lambda =6.83\mathrm{E}5\mathrm{W}/\mathrm{m}$ and a resonance shift of $\mathrm{\Delta }\lambda /E=1.47\mathrm{E}-16{\mathrm{m}}^2/\mathrm{V}$.

The partial removal of a section of the core from a continuous D-shaped optical fiber is presented. In the core removal process, selective chemical etching is used with hydrofluoric (HF) acid. A 25% HF acid solution removes the cladding material above the core, and a 5% HF acid solution removes the core. A red laser with a wavelength of 670 nm is transmitted through the optical fiber during the etching. The power transmitted through the optical fiber is correlated to the etch depth by scanning electron microscope imaging. The developed process provides a repeatable method to produce an optical fiber with a specific etch depth.

A fiber-optic sensor used to detect volatile organic compounds is described. The sensor consists of a single-mode D-fiber with a $2.5\text{\hspace{0.17em} μm}$ polydimethylsiloxane layer. The layer is applied to the fiber flat after removal of a section of the fiber's cladding to increase evanescent interaction of the light with the layer. Absorption of volatile organic compounds into the polymer alters the refractive index of the layer, resulting in a birefringent change of the fiber. This change is observed as a shift in polarization of the light carried by the fiber. The sensor has a short length of 3 cm and a response time of around 1 s. The sensor is naturally reversible and gives an exponential response for gas and liquid concentrations of dichloromethane and acetone, respectively.

We present a method for fabricating an in-fiber electro-optic polymer waveguide within a D-shaped optical fiber. A combined process of selective chemical etching and spin coating creates a 2-cm in-fiber poly(methyl methacrylate)-DR1 dye polymer waveguide section with an overall insertion loss of ∼1.6 dB at 1550 nm. Numerical simulations show that, for in-fiber polymer waveguides to have low loss, the polymer layer’s thickness must be kept below a certain value so that it will not support slab waveguide modes. Long transition regions between the unetched fiber and the polymer waveguide section also reduce loss. We analyze the efficiency of an in-fiber polymer waveguide by simulating its theoretical performance as an electro-optic modulator.