Design and fabrication of optical code generating devices based on plastic optical fiber (POF) for security access-card system is presented. The POF waveguide coupler will utilize two basic designs: 1 × 2 Y-branch coupler as the main device structure and 1 × 2 asymmetric coupler which allows non-symmetric optical power splitting. The Y-branch coupler are based on two designs: A metalbased POF coupler with a hollow taper waveguide and an acrylicbased POF coupler with optical glue for the taper waveguide region. The Y-branch device is composed of input POF fiber, middle taper waveguide and output POF fibers. Simulation based on non-sequential ray tracings have been performed on both types of POF couplers. Low cost aluminum and acrylic based materials are used for the substrates. Fabrications of the POF couplers are done by producing the device mold insert using CNC machining tool and POF fibers are then slotted into the Y-branch coupler mold insert. The insertion loss for both devices are about 8 dB.
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