Methods for processing a multi-fiber ferrule using a laser

A method for processing a multi-fiber ferrule for a multi-fiber fiber optic connector, the multi-fiber ferrule including a ferrule body defining a plurality of openings that extend therethrough, the ferrule body having a plurality of optical fibers potted within the plurality of openings, the method comprising:

• polishing a distal end face of the ferrule;
• and
• removing a portion of the distal end face of the multi-fiber ferrule by using a laser process in which a laser is directed across the distal end face of the multi-fiber ferrule to ablate the portion of the distal end face;
• wherein the step of removing the portion of the distal end face includes moving the laser across the distal end face of the multi-fiber ferrule at a first laser beam intensity to form a recessed region on the distal end face of the multi-fiber ferrule, and moving the laser across a central region on the distal end face of the multi-fiber ferrule at a second laser beam intensity to form the central region with a raised region relative to the recessed region, the plurality of optical fibers protruding outwardly from the central region such that the central region is recessed relative to the plurality of optical fibers;
• wherein no portions of the distal end face of the multi-fiber ferrule are higher than the central region in which the plurality of optical fibers protrude;
• wherein the laser moves in a linear moving direction along a plurality of parallel lines in which a plurality of laser beam pulses are directed at the distal end face of the multi-fiber ferrule;
• wherein the laser defines a pulse spot on the distal end face of the multi-fiber ferrule each time the laser is pulsed, the pulse spot having a spot coverage area;
• wherein spot coverage areas of adjacent pulse spots along a given one of the plurality of parallel lines overlap one another by at least 50 percent in the linear moving direction;
• wherein adjacent ones of the plurality of parallel lines are spaced apart from one another by a distance less than a spot diameter of the adjacent pulse spots such that pulse spots of the adjacent parallel lines have spot coverage areas that overlap, the spot coverage areas of the adjacent parallel lines overlapping by at least 20 percent;
• and
• wherein the percent of overlap in the linear moving direction of the spot coverage areas of adjacent pulse spots along one of the plurality of parallel lines is greater than the percent of overlap of the spot coverage areas of the adjacent parallel lines.