SBIR-STTR Award

Demonstrate the feasibility to injection mold precise ceramic fiber optic ferrules using a high density, low pressure molding process and a rapid, fully automated, manufacturing cell. Injection molding has the potential to reduce the cost of ferrule manufacturing by molding blanks to near net shape, reducing the number of grinding operations, and to such precision that critical grinding steps are reduced or eliminated. However, the process is inherently more expensive than the process currently used to produce blanks, limiting the advantage of a near net shape. Precise process control for each individual part must be maintained during thermal operations to control minute distortions common to all ceramic product that will negate the advantage offered by a dimensionally precise blank. A high density, low pressure molding system provides low processing shrinkages and stresses for precise dimensional control. The proposed cell will produce blanks an order of magnitude faster than conventional processes at a cost similar to an extruded blank and with precise process control for each part. The process is continuous and economically dependent upon batch size, making possible the cost effective porduction of small volumes as well.

Develop a prototype ceramic injection molding manufacturing cell for the production of low cost single-mode fiber optic ferrules, the critical components in fiber optic connectors. Currently, US users of fiber optic technology, including the military, are dependent upon foreign sources. The key to reducing the cost of manufacture of ferrules is to reduce or eliminate grinding steps in ferrule production. Phase 1 demonstrated superior control of part distortion during processing. Successfully extending this technology to high volume production should dramatically reduce the cost of manufacturing ferrules.

Benefits:
Establish a low cost, domestic manufacturer of fiber optic ferrules, the critical components in fiber optic connectors. The technology will also be extended to the manufacture of ceramic micro-components. The projected market for all micro-components is $14 billion by 2005.

Keywords:
fiber optic ferrules micro-components ceramic injection molding fiber optic connectors