Cost-effective side-coupling polymer fiber optics for optical interconnections

A method for cutting mirrors into polymer optical fibers, each fiber having an input and an output end, each mirror having an intensity output and comprising a notch having a depth and at least one surface angled with respect to a central axis of the optical fiber, the method comprising the steps of:

• cutting the notch in the optical fiber with a knife having a blade portion positioned at a predetermined angle with respect to the central axis;
• simultaneously with the cutting, controlling the movement of the knife in at least two directions relative to the optical fiber with a stage upon which the knife is mounted;
• simultaneously with the cutting, directing light from a light source having an input power through the input end of the optical fiber to be cut;
• simultaneously with the cutting, measuring residue optical power at the output end with an optical power meter connected to the output end, wherein the residue optical power is the difference between the input power and the intensity output of the mirror;
• simultaneously with the cutting, generating a feedback signal from a processor to the stage based upon the residue optical power signal, whereby the stage directs the knife to cut the notch to a depth until the residue power and thus the intensity output reaches a predetermined limit.