Review: 3D printing of optical fibers and optical fiber preforms

The integration of 3D printing technology into optical fiber fabrication has significantly advanced the field of photonics and telecommunications. As traditional fiber manufacturing methods face limitations in terms of precision, scalability, and customization, the emergence of additive manufacturing presents new opportunities for next-generation optical fibers. This comprehensive review expands on the latest developments in 3D-printed optical fibers, exploring various printing techniques, material innovations, and application areas. We examine the fundamental properties of 3D-printed fibers and their impact on performance metrics such as light transmission, flexibility, and robustness. Special focus is given to the challenges in scaling up production, achieving high-quality prints, and optimizing material properties for different applications, including fiber optics, sensors, and communications systems. The paper also highlights the role of new materials, including polymers, glass composites, and functionalized inks, in enhancing the functionality of printed fibers. Furthermore, the review critically discusses the hurdles in commercialization and implementation, such as material consistency, processing speeds, and integration with existing manufacturing frameworks. To overcome these challenges, the review proposes potential solutions and outlines a clear roadmap for future research aimed at realizing the full potential of 3D-printed optical fibers in commercial and industrial applications. This work serves as an authoritative resource for researchers and engineers working to advance the field of optical fiber technology through additive manufacturing.