Patent Publication Number: US-8523459-B2

Title: Optical ferrule assemblies and methods of making the same

Description:
RELATED APPLICATIONS 
     This application is a divisional application of prior application Ser. No. 12/339,238, filed Dec. 19, 2008, now U.S. Pat. No. 8,109,679 which claims the benefit of U.S. Provisional Application No. 61/117,941, filed Nov. 25, 2008, which are both incorporated by reference herein in their entireties. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to optical fiber assemblies, and more particularly, to optical ferrule assemblies and methods for making the same. 
     TECHNICAL BACKGROUND 
     Optical fiber communication systems typically include optical fiber connectors. For instance, one or more optical fiber connectors can be used to join adjacent segments of optical fiber together for creating optical connections that can be connected, disconnected, and/or reconfigured as desired. For instance, one or more optical fiber connectors can be used for joining an optical fiber segment to an optical device or joining two optical fiber segments. Typical optical fiber connectors include a conventional ferrule designed to hold an optical fiber in an appropriate orientation for optically joining the end of the optical fiber segment to an optical interface of an optical device or another optical fiber segment. 
     Conventional optical ferrule assemblies include one or more optical fibers that typically extend (i.e., protrude) from a face of a conventional ferrule at an appropriate distance from the face of the ferrule. Thereafter, the end of the optical fibers are shaped and/or polished using a conventional mechanical polishing process to smooth and reduce defects in the face of the optical fiber end for reducing optical insertion loss. In other words, reducing defects in the optical fiber end faces enhances the physical contact between the end faces of mating optical fibers, thereby improving optical coupling at the interface therebetween. 
     SUMMARY 
     Multifiber ferrule assemblies and methods for manufacturing multifiber ferrule assemblies are disclosed. In one embodiment, a finished multifiber ferrule can be provided with a front end having a first front surface that extends beyond a second front surface, thereby inhibiting interaction with a laser beam during processing. A plurality of optical fibers can be fixed within respective optical fiber bores of the finished multifiber ferrule and extend from respective optical fiber bore openings to a position beyond the first front surface. The plurality of optical fibers can be processed by cutting and polishing with a laser beam for providing each optical fiber with a final polished end surface located beyond the first front surface. In further embodiments, an offset structure is positioned with respect to a finished multifiber ferrule after cutting and polishing the optical fibers. Additionally, several different methods for making the multifiber ferrule assemblies using a laser for cutting and polishing the optical fibers are disclosed. 
     It is to be understood that both the foregoing general description and the following detailed description present example and explanatory embodiments of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention and are incorporated into and constitute a part of this specification. The drawings illustrate various example embodiments of the invention, and together with the description, serve to explain the principles and operations of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features, aspects and advantages of the present invention are better understood when the following detailed description of the invention is read with reference to the accompanying drawings, in which: 
         FIG. 1  is an exploded perspective view of a explanatory fiber optic connector having a multifiber ferrule assembly in accordance with aspects of the present invention; 
         FIG. 2  is an assembled view of another explanatory fiber optic connector; 
         FIG. 3  is a perspective view of a finished multifiber ferrule of the multifiber ferrule assembly illustrated in  FIGS. 1 and 2 ; 
         FIG. 4  is a perspective view of another finished multifiber ferrule incorporating example aspects of the present invention; 
         FIG. 4A  is an enlarged view of portions of the finished multifiber ferrule of  FIG. 4 ; 
         FIG. 5  is a sectional view of the finished multifiber ferrule along line  4 - 4  of  FIG. 3 ; 
         FIG. 6  is a sectional view similar to  FIG. 4  with a plurality of optical fibers fixed to the finished multifiber ferrule; 
         FIG. 7A  is an enlarged view of portions of  FIG. 5 ; 
         FIG. 7B  is a schematic illustration demonstrating the optical fibers being processed; 
         FIG. 7C  is a view illustrating portions of the multifiber ferrule assembly after the optical fibers are processed with the fibers having an effective fiber height “h” for mating in an optical connection; 
         FIG. 7D  illustrates the multifiber ferrule assembly of  FIG. 7C  being mated in an optical connection; 
         FIG. 8  is a schematic view of a first explanatory apparatus and method for processing multifiber ferrule assemblies; 
         FIG. 8A  is detailed view of a handler assembly of the apparatus of  FIG. 8 ; 
         FIGS. 8B and 8C  are detailed perspective views of portions of the handler assembly shown in  FIG. 8A ; 
         FIGS. 9-11  are respective schematic views of other explanatory apparatus and methods for processing multifiber ferrule assemblies; 
         FIG. 12  is an exploded perspective view of another multifiber ferrule assembly in accordance with further aspects of the present invention; 
         FIG. 13  is an assembled perspective view of the multifiber ferrule assembly of  FIG. 12 ; and 
         FIG. 14  is a perspective view of still another multifiber ferrule assembly. 
     
    
    
     DESCRIPTION OF EXAMPLE EMBODIMENTS 
     The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which example embodiments of the invention are shown. However, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like reference numbers refer to like elements throughout the various drawings. 
       FIG. 1  is an exploded perspective view of a fiber optic connector  100  including an example multifiber ferrule assembly  20  for mating in an optical connection. As shown, the multifiber assembly comprises an MT-type multifiber ferrule although other types of multifiber ferrules may be used in further examples. 
     The fiber optic connector  100  can comprise various configurations. In one example, aspects of the multifiber ferrule assembly  20  can be incorporated in the fiber optic connector illustrated and described in U.S. Pat. No. 7,077,576 to Luther et al., issued on Jul. 18, 2006, the disclosure of which is incorporated by reference in its entirety.  FIG. 1  illustrates an exploded view of one example fiber optic connector  100  while  FIG. 2  illustrates an assembled view of another example fiber optic connector  200  that can include like parts represented by identical reference numbers. The optic connectors  100 ,  200  are just examples of fiber optic connectors that can incorporate a multifiber ferrule assembly  20  in accordance with aspects of the present invention. 
     Referring to  FIG. 1 , the example fiber optic connector  100  can include a multifiber ferrule assembly  20  for mating in an optical connection. The multifiber ferrule assembly  20  includes a finished multifiber ferrule  30  with a front end  30   a  and a rear end  30   b  and one or more optical fibers (not shown for clarity) inserted into finished multifiber ferrule  30 . As used herein, “finished multifiber ferrule” means that after the optical fibers are inserted into the ferrule the front end of the ferrule does not require a mechanical grinding or polish for creating the desired geometry for the ferrule and/or optical fibers; however, a cleaning or wiping process or the like may be used on the finished multifiber ferrule. Finished multifiber ferrule  30  can include at least one guide pin hole  34  that is adapted to receive a respective guide pin  36  to align the finished multifiber ferrule  30  with an opposing ferrule of another mating fiber optic connector. In the exemplary embodiments shown herein, the finished multifiber ferrule  30  is and MT-type ferrule with a ferrule body defining a pair of guide pin holes  34  configured to receive respective guide pins  36 . The guide pin holes  34  can extend along a longitudinal axis  38  ( FIG. 2 ) of the finished multifiber ferrule  30 . A guide pin keeper  37  can be positioned adjacent a rear face of a rear end  30   b  to secure the guide pins  36 . The guide pins  36  can be secured such that the free ends of the guide pins  36  protrude forwardly from the end face of the front end  30   a . The guide pins  36  can be secured to protrude a sufficient distance to engage guide pin holes in the ferrule of the mating fiber optic connector, thereby aligning the optical fibers mounted within the respective bores of the opposing ferrules. 
     As further illustrated in  FIG. 1 , the optic connector  100  may optionally comprise a spring seat  104 , a coil spring  110 , a spring push  120 , a lead-in tube  130  and a generally hollow connector housing  102 . Other than the multifiber ferrule assembly  20 , various components of the fiber optic connector  100  are optional and the functions of these components are generally known. Thus, each optional component will not be described in detail herein except as necessary to enable one of ordinary skill in the art to understand and fully appreciate the invention. Furthermore, it will be readily understood by those skilled in the art that each of the optional components may be configured in any number of different shapes, sizes and constructions without departing from the intended scope of the invention, as defined by the appended claims. 
     The optional spring seat  104  of the example embodiment shown in  FIG. 1 , can be positioned adjacent the rear face of the rear end  30   b  between the finished multifiber ferrule  30  and the coil spring  110 . An opening  106  extending lengthwise through the spring seat  104  can be configured to permit the lead-in tube  130  and the end portions of the optical fibers (not shown) to pass through the spring push  120  to the rear face of the finished multifiber ferrule  30 . The lead-in tube  130  can be positioned within an opening  122  of the spring push  120 , an opening  112  of the coil spring  110  and the opening  106  of the spring seat  104 . An opening  132  extending lengthwise through the lead-in tube  130  receives and guides the end portions of the optical fibers of the fiber optic cable in respective bore openings  52  of the finished multifiber ferrule  30 . 
     The fiber optic connector  100  can include a mounting structure positioned with respect to the multifiber ferrule assembly. For example, as shown in  FIG. 2 , the mounting structure can comprise a housing  102  with the multifiber ferrule assembly  20  at least partially positioned within the housing  102 . As shown, the finished multifiber ferrule  30  and guide pins  36 , the guide pin keeper  37 , the spring seat  104 , the coil spring  110 , a forward portion  124  of the spring push  120  and the lead-in tube  130  can be positioned within the connector housing  102 . In one example, flexible arms  126  provided on spring push  120  can extend lengthwise from the forward portion  124  to engage openings  103  formed in the connector housing  102  for securing the spring push  122  with the connector housing  102 . A forward mechanical stop (not visible) can be provided on the interior surface of the connector housing  102  so that the finished multifiber ferrule  30  is movable when the disposed within the connector housing  102 , but retained therein. The finished multifiber ferrule  30  is biased in the forward direction by the coil spring  110  and the spring seat  104 . 
       FIG. 3  is a perspective view of the finished multifiber ferrule  30  of the multifiber ferrule assembly  20  illustrated in  FIGS. 1 and 2 . Of course, the concept of the disclose may be practiced with other finished multifiber ferrules. Finished multifiber ferrule  30  can be fabricated in a wide variety of ways. For example the finished multifiber ferrule  30  may be fabricated by an injection molding process, the machining process and/or other fabrication methods. The finished multifiber ferrule  30 , for instance, may be fabricated as an initial multifiber ferrule by an injection molding process. A subsequent machining process may be carried out on portions of the molded multifiber ferrule in order to increase dimensional precision and provide the finished multifiber ferrule. As shown in  FIG. 3 , certain dimensions of the finished multifiber ferrule may therefore be established prior to fabricating the multifiber ferrule assembly  20 . 
     As shown, in  FIG. 3 , the front end  30   a  of the finished multifiber ferrule  30  can include a first front surface  40  and at least a second front surface  50 . As shown in  FIG. 4 , the first front surface  40  extends a first distance “d” beyond the second front surface  50  and the second front surface  50  includes a plurality of optical fiber bore openings  52 . In one example, an offset structure, such as at least one pedestal  42 , can include the first front surface  40 . Although a single pedestal may be used, two or more pedestals may be incorporated in other examples. For instance, as shown in  FIG. 3 , the pedestal  42  can include a first pedestal  42   a  and a second pedestal  42   b  wherein the first front surface  40  can be defined by the first pedestal  42   a  and the second pedestal  42   b . The at least one pedestal  42  can be located on one side of the second front surface. Moreover, the at least one pedestal can comprise a plurality of pedestals located on one side, opposite sides, adjacent sides or other configurations. For instance, as shown in  FIG. 3 , the at least one pedestal  42  can be provided with a first pedestal  42   a  and a second pedestal  42   b  disposed on opposite sides of the second front surface  50 . As illustrated, disposing the first pedestal  42   a  and second pedestal  42   b  on opposite sides positions the bore openings  52  substantially between the first pedestal  42   a  and the second pedestal  42   b . In further configurations, it is contemplated that the bore openings  52  may be located such that they are not substantially between the first pedestal  42   a  and the second pedestal  42   b . As shown in  FIG. 3 , the guide pin holes  34  can optionally extend through the first front surface  40  of the corresponding pedestals  42   a ,  42   b.    
       FIGS. 4 and 4A  illustrate an alternative example of a finished multifiber ferrule  230  including many of the features of the finished multifiber ferrule  30  discussed above. As shown, however, the finished multifiber ferrule  230  includes an alternative pedestal including a first pedestal  242   a  and a second pedestal  242   b  wherein a first front surface  240  can be defined by the first pedestal  242   a  and the second pedestal  242   b . The at least one pedestal  242  can be located on one side of the second front surface. Moreover, the at least one pedestal can comprise a plurality of pedestals located on one side, opposite sides, adjacent sides or other configurations. For instance, as shown in  FIG. 4 , the at least one pedestal can be provided with a first pedestal  242   a  and a second pedestal  242   b  disposed on opposite sides of a second front surface  250 . As illustrated, disposing the first pedestal  242   a  and second pedestal  242   b  on opposite sides can arrange bore openings  252  substantially between the first pedestal  242   a  and the second pedestal  242   b . In further configurations, it is contemplated that the bore openings  252  may be located such that they are not substantially between the first pedestal  242   a  and the second pedestal  242   b . As shown in  FIGS. 4 and 4A , each of the pedestals  242   a ,  242   b  can be arranged to extend between a corresponding guide pine hole  234  and the bore openings  252 . For example, as shown in  FIG. 4A , the first pedestal  242   a  can be positioned between the guide pin hole  234  and the bore openings  252 . Likewise, the second pedestal  242   b  can be positioned between the other guide pin hole and the bore openings. Therefore, it will be appreciated the first front surface  240  can be isolated from the guide pin holes  234  since the guide pin holes do not extend through the first front surface  240 . Such an arrangement can help prevent debris or other contaminants associated with the guide pins  36  from corrupting the otherwise clean first front surface  240 . Moreover, the pedestals  242   a ,  242   b  can act as barriers to inhibit, such as prevent, debris or other contaminants associated with the guide pins from propagating toward the bore openings  252  and associated optical fibers extending from the bore openings  252 . 
     Example methods for manufacturing a multifiber ferrule assembly are described with respect to multifiber ferrule assembly  20  having a finished multifiber ferrule, but are applicable to any suitable multifiber ferrule or assembly. For instance, the concepts disclosed herein may be used with ferrules that require mechanical polishing or the like if desired and do not require a finished multifiber ferrule. As shown in  FIG. 5  the explanatory method includes the step of providing the finished multifiber ferrule  30 . Thereafter, one or more optical fibers  60  are inserted into finished multifiber ferrule for fixing the optical fibers  60  to the finished multifiber ferrule  30  such as with an adhesive.  FIG. 6  illustrates a cross-section showing one of the optical fibers  60  being fixed within a corresponding bore  52  with the understanding that each optical fiber  60  can be fixed to a corresponding one of the bores  52  in a similar manner. An adhesive  54  or the like is used for fixing the position of the optical fibers  60  within the corresponding bore  52 . As shown in  FIG. 7A , the plurality of optical fibers  60  extend from a respective bore  52  to a position beyond the first front surface  40 . For instance, as shown in  FIG. 7A , a preprocessed end portion  61  of the optical fibers  60  extend an unprocessed distance “H” from the first front surface  40 . By way of example, unprocessed distance H is about about 10 nanometers or more, but other suitable unprocessed dimensions H are possible. 
     As shown, the finished multifiber ferrules  30 ,  230  can also include an optional backdraft portion  32 ,  232 . This backdraft portion  32  aids processing according to the disclosed methods by providing a relief during the processing and inhibiting marking and/or damage to the front end of the ferrule. Specifically, the backdraft portion inhibits interaction between a laser beam and/or debris during cutting and/or polishing, thereby inhibiting marking and/or damage to the front end of the ferrule. As shown in  FIG. 7A , the backdraft portion  32  can include a surface  32   a  that is angled with respect to the longitudinal axis of the finished multifiber ferrule  30 . Backdraft portion  32  can have any suitable angle such as between 30 to 45 degrees from the front face, but other suitable angles are possible. Further, the backdraft can start at any suitable distance from bores  52  so long as dimensions and structural integrity of the ferrule are preserved. As further illustrated, the backdraft portion  32  can also be optionally recessed rearward from the second front surface  50 . By way of example, a shoulder  32   b  can be formed adjacent to the backdraft, thereby permitting the backdraft portion  32  to be recessed rearward from the second front surface  50 . For instance, shoulder  32   b  can have a depth of about 2 microns or greater. 
     The methods further include the step of processing the plurality of optical fibers  60  as shown in  FIG. 7B . Processing can include cutting and/or polishing the preprocessed end portion  61  of optical fiber  60 . In one example, the step of processing end portion  61  includes cutting and polishing the plurality of optical fibers  60  with a laser beam  72  of a laser  70  in one or more steps. For instance, separate steps may be used for cutting and polishing optical fibers  60  with laser  70 , but cutting and polishing may also occur in one step with laser  70 . Any suitable type of laser and/or mode of operation for the laser is possible. By way of example, laser  70  may be a CO 2  laser operating in the pulse, continuous, or other suitable mode. The angle between the laser beam  72  and optical fibres  60  may also be adjusted to produce the desired angle on the ends of optical fibers  60  such as 12 degrees, 8 degrees, or flat. Due to the distance between the preprocessed end portion  61  and the second front surface  50 , the laser beam  72  can substantially avoid interaction with the finished multifiber ferrule  30  during cutting and polishing of the plurality of optical fibers  60 . Optional backdraft portion is provided to further reduce the probability of interaction between refracted portions of the laser beam/debris and the finished multifiber ferrule. For instance, as schematically shown in  FIG. 7B , the front end  30   a  of the finished multifiber ferrule  30  can include a backdraft portion  32  and the laser beam  72  can be designed to cut and/or polish the plurality of optical fibers  60  in a general direction from the second front surface  50  toward the backdraft portion  32 . 
     As shown in  FIG. 7C , once the processing of the optical fibers  60  is complete, each optical fiber  60  can be provided with a final polished end surface  62  located beyond the first front surface  40 . The first front surface  40  is disposed relative to the optical fibers  60  with an effective fiber height for mating in an optical connection as shown in  FIG. 7D . In other words, optical fibers  60  have a short protrusion beyond the first front surface  40 , thereby providing the effective fiber height for physical contact with optical fibers of a complimentary optical fiber connector.  FIG. 7D  depicts the optical mating with a complimentary multifiber optical assembly  500  and an interface  520  therebetween. Thus, after processing, a plurality of optical fibers  60  are fixed to the finished multifiber ferrule  30 , wherein the plurality of optical fibers  60  extend from a respective one of the optical fiber bore openings  52 . Each optical fiber  60  includes a final polished end surface  62  located at a second distance “h” (i.e., a short protrustion) beyond the first front surface  40 , wherein the first front surface  40  is configured to present each of the fibers  60  with an effective fiber height for mating in an optical connection. As shown in  FIG. 7C , in one example, the effective fiber height is substantially equal to the second distance “h” although the effective fiber height may be greater or less than the second distance “h” in further examples. 
     As mentioned above with reference to  FIG. 5 , the first front surface  40  extends a first distance “d” beyond the second front surface  50 . As shown in  FIG. 7C , the first distance “d” can be greater than the second distance “h” although the first distance “d” can be substantially equal or less than the second distance “h” in other variations. By way of example, the first distance can be at least 15 microns or even at least 30 microns. Second distance “h” can have any suitable distances depending on the application. For example, the second distance “h” can be from about 0.5 microns to about 5 microns, such as from about 1 micron to about 3 microns. Likewise, the first distance “d” can have any suitable distances depending on the application such at least 1 micron. Moreover, any suitable combinations of the first distance “d” and the second distance “h” are possible so long as the desired optical performance is accomplished. For instance, the first distance “d” may be about 30 to about 40 microns and the second distance “h” is between about 0.5 microns to about 5 microns. In other embodiments, the second distance “h” is at least 1 micron and in other embodiments the second distance is between about 1 micro and about 3 microns. A long protrustion of the optical fibers is defined by the sum of first distance “d” and second distance “h”. The particular dimensions for first distance “d” and second distance “h” may depend of the ferrule design used. 
     For instance, suitable values for the multifiber ferrule assemblies may vary depending on the type of material selected for the ferrule. By way of example, a thermoset ferrule may have a co-planarity in the range of about 75 nanometers to about 300 nanometers and a long protrusion (i.e., first distance “d” plus second distance “h”) of about 15-20 nanometers above the ferrule face and a short protrusion (i.e., second distance “h”) of about 0.5-5 nanometers above the bumpers of the ferrule. On the other hand, a thermoplastic ferrule may have a co-planarity in the range of about 200 nanometers to about 400 nanometers and a long protrusion of about 30-35 nanometers above the ferrule face and a short protrusion of about 0.5-5 nanometers above the bumpers of the ferrule. As known in the art, co-planarity is the sum of the deviation of the longest protruding optical fiber plus the deviation of the shortest protruding optical fiber from a least fit square line fitted to the optical fiber protrusion profile for the given finished multifiber ferrule assembly. 
     Processing of the plurality of optical fibers  60  can be carried out in various ways using laser  70 . By way of example, the multifiber ferrule assembly may move with respect to the laser beam, vice versa, or combinations of both movements.  FIG. 8  is a schematic illustration of an explanatory apparatus  800  and method for processing multifiber ferrule assemblies  20 . As shown, apparatus  800  includes a base  802  having an adjustable mounting structure such as mounting rails for positioning laser  70  and an optical path adjustment device  804  in the desired locations. Additionally, apparatus  800  includes a rotatable work holder such as a turntable  300  mounted behind the optical path adjustment device  804 . As depicted, the finished multifiber ferrule  30  can be rotated on turntable  300  with respect to the laser beam  72  during the step of cutting and polishing. For example, a plurality of multifiber ferrule assemblies  20  may be mounted about the periphery of turntable  300  for improving cycle times. 
     Furthermore, the multifiber ferrule assemblies  20  may be secured directly to the work holder or can be held in a modular portion of the work holder for processing, inspection, geometry measurement, and the like. As shown in  FIG. 8A , turntable  300  includes a handler assembly  804  attached thereto for loading the multifiber ferrule assembly therein and attaching and referencing the same relative to the turntable  300  and laser beam  72 . Handler assembly  804  may also be suitable for securing to a station for inspection/measurement of the multifiber ferrule assembly after processing. As shown, handler assembly  804  uses a clamping structure on a mounting arm  820  with a quick attach/release feature  806  for securing an insert assembly  810  therein. Handler assembly  804  also includes a stop  808  attached to mounting arm  820  for positioning the multifiber ferrule assembly in the proper location.  FIG. 8B  and  FIG. 8C  respectively depict detailed perspective views showing a multifiber ferrule assembly loaded within insert assembly  810  and the mounting arm  820  of handler assembly  804 . As shown in  FIG. 8B , multifiber ferrule assembly  20  is loaded into insert assembly  810  so it is secured between a first portion  812  and a second portion  814  with a portion of the multifiber ferrule  30  extending beyond first portion  812 . Thereafter, insert assembly  810  is placed into mounting arm  820  until multifiber ferrule  30  contacts stop  808 , then attach/release feature  806  is toggled to clamp the insert assembly in position for processing. Of course, other suitable constructions and/or assemblies are possible for the handler assembly depending on the apparatus, mounting surface, etc. 
     An explanatory process includes securing multifiber ferrule assembly  20  in handler assembly  804  and then placing the loaded handler assembly  804  in turntable  300 . Specifically, handler assembly  804  includes a port having a hardstop (not shown) for receiving and precisely positioning the multifiber ferrule in handler assembly  804 . The port of handler assembly  804  may also provide protection from areas of the multifiber ferrule that need not have exposure to the laser beam. Thereafter, a first laser processing step cuts optical fibers  60  longer than required by oscillating the same back and forth with respect to laser beam  72 , thereby cutting all of the optical fibers. Then the optical fibers  60  are cleaned using an air/alcohol mix or other suitable cleaning or wiping process. Next, a second laser processing step is used for polishing the ends of the cut optical fibers to the desired length with respect to the ferrule end face, again by oscillating the optical fibers with respect to the laser beam  72  for polishing the same. Moreover, turntable  300  can move at any suitable speed for processing the multifiber ferrule assembly for the given operation parameters of laser  70 . By way of example, the multifiber ferrule can move at about 25 millimeters per second back and forth when using a 50-watt CO 2  laser operated in the CW mode at 20 kHz available from SYNRAD Inc. of Mukilteo, Wash. Of course, other suitable operating parameters are possible for the speed and/or laser operating characteristics. After cutting and polishing is finished, the handler assembly  804  can be removed from turntable  300  for securing in a station for inspection and measuring the geometry of the optical fibers. If the multifiber ferrule assembly does not meet the desired requirements and/or geometry the handler assembly  804  may be placed back into the turntable for further processing. 
     As shown, the backdraft portion  32  can face outward and the laser  70  can be operated radially inward from each respective multifiber ferrule assembly  20  as turntable  300  rotates about a rotation axis  304 . In one example, the turntable  300  can be incrementally rotated to appropriately position one of the multifiber ferrule assemblies  20  with respect to the laser  70 . Additionally, the laser  70  can be designed to translate relative to each optical fiber  60  for individual processing of the corresponding fibers of the multifiber ferrule assembly  20 . In other embodiments, the laser  70  rotates, thereby oscillating (i.e., moving back and forth) the laser beam  72  across all of the optical fibers during cutting and/or polishing. Once complete, the turntable  300  may be rotated such that the next multifiber ferrule assembly can be processed in turn. While, processing of the next multifiber ferrule assembly  20 , the first processed multifiber ferrule assembly  20  can be removed and replaced with another multifiber ferrule assembly for processing in turn. 
     Work holders for multifiber ferrules assemblies of the apparatus can have any suitable construction/operation so long as it provides the desired repeatability, tolerances, and the like for the process. For instance, the process and apparatus should produce a relatively small co-planarity among the optical fibers. Illustratively, the co-planarity among the optical fibers should be about 500 nanometers or less, other values of co-planarity such as 400 nanometer or less are also possible. Of course, bigger values of co-planarity are possible if they provide the desired optical performance. By way of example, turntable  300  is rotatably mounted on a suitable air bearing structure such as air bearing spindle  302  that is supported by a cushion of compressed air such as available from Professional Instruments Company of Hopkins, Minn., thereby maintaining highly accurate and repeatable motion such as precise runout and/or inhibiting vertical displacement during processing. For instance, the air bearing spindle  302  provides accurate and repeatable motion such as having a relatively small vertical displacement in the Z-direction such as 25 nanometers or less, which aids in maintaining co-planarity of the optical fibers. Other suitable types of arrangements using an air bearing spindle and/or other air bearing structures are possible such as discussed with respect to  FIG. 10  and  FIG. 11 . Additionally, laser beam  72  need not cut through the respective optical fibers within the multifiber ferrule assembly  20  in one pass. In other words, the multifiber ferrule assembly  20  can oscillate relative to the laser  70 , thereby forming the cut through the optical fibers in several passes past laser  70 . For instance, the optical fibers may make between three and ten oscillations past laser  70  before being completely cut therethrough, but other values are possible such as one pass or more than ten passes. Of course, other embodiments may move the laser or laser beam relative to the ferrule during processing. 
       FIG. 9  depicts a schematic illustration of another explanatory apparatus  900  and method for processing multifiber ferrule assemblies  20 . Specifically, apparatus  900  translates laser beam  72  relative to multifiber ferrule assembly  20  during the step of cutting and polishing. Apparatus  900  includes laser  70 , an F-theta lens  904 , and a  2 -axis galvanometer scanner  906  available from ScanLab America, Inc. of Naperville, Ill. Simply stated, the galvanometer scanner  906  moves the laser beam in the desired patterns to cut and polish the optical fibers of multifiber ferrule assembly  20 . Although this apparatus is simpler because the work piece does not have to move, the co-planarity using apparatus  900  may more difficult to control compared with apparatus  800 . Moreover, since the work piece does not move it is easier to accommodate different types of multifiber ferrule assemblies such as different cable sizes, different lengths of cable, etc. Additionally, apparatus  900  preferably includes a handler assembly (not shown) for repeating the positioning the multifiber ferrule assembly relative to the path of laser beam  72 , protecting other portions of the assembly, and/or for inspection of the processed assembly. 
       FIG. 10  shows a hybrid apparatus  1000  that combines concepts/features of apparatus  700  and apparatus  800  where the workpiece is stationary and the laser beam moves for cutting the plurality of optical fibers of multifiber ferrule assembly  20 . Apparatus  1000  includes a component mounted on a turntable  300  that rotates on air bearing spindle  302 . Specifically, turntable  300  has a mirror  1002  attached thereto for rotating mirror  1002  as depicted by the arrows, thereby sweeping laser beam  72  back and forth through a F-theta lens  904 . The F-theta lens  904  focuses the laser beam and maintains the focal point of the laser in a plane as it translates to maintain the desired co-planarity.  FIG. 11  shows another apparatus  1100  that is similar to apparatus  1000  since the workpiece is stationary and the laser beam moves for cutting the plurality of optical fibers of multifiber ferrule assembly  20 . However, apparatus  1100  uses a linear air bearing  1004  for moving mirror  1002 , thereby sweeping laser beam  72  back and forth through a F-theta lens  904 . Other suitable configurations are possible for sweeping the laser beam so long as the desired repeatability and tolerances are maintained. 
     Additionally, the concepts disclosed herein may be practice with other suitable ferrules where the optical fibers extend a suitable distance from the front face so that the laser beam does not mark and/or damage the same. For instance,  FIGS. 12 and 13  illustrate another example of a multifiber ferrule assembly  420 . The multifiber ferrule assembly  420  includes an offset structure  442  including a first front surface  440  and a finished multifiber ferrule  430  with a second front surface  450  with a plurality of fiber bore openings including a plurality of optical fibers  460  extending from a respective one of the optical fiber bore openings. Simply stated, instead of using a backdraft the ferrule has an offset structure that is a removable portion from the portion that has the optical fibers attached thereto (i.e., the finished multifiber ferrule) for inhibiting interaction between the laser beam during cutting and polishing and then attached afterwards. A method of manufacturing the multifiber ferrule assembly is similar to the method described above and includes the steps of providing the offset structure  442  and the finished multifiber ferrule  430  and fixing the plurality of optical fibers  460  to the finished multifiber ferrule  430 , wherein the plurality of optical fibers  460  extend from a respective one of the optical fiber bore openings to a position beyond the second front surface  450 . Thereafter, cutting and polishing the plurality of optical fibers with a laser beam provides the optical fibers with a final polished end surface located beyond the second front surface  450 . As shown in  FIG. 13 , the offset structure  442  is attached to the finished multifiber ferrule  430  after the step of cutting and polishing. In this embodiment, protrusions (not numbered) extending from the backside of offset structure  442  fit into bores (not numbered) of finished multifiber ferrule  430 . Moreover, protrusions are suitable for receiving guide pins from the front side, thereby allowing alignment and mating with a complementary fiber optic connector. As shown in  FIG. 13 , the final polished end surface of each optical fiber  460  is located beyond the first front surface  440  for presenting the optical fibers  460  with an effective fiber height for mating in an optical connection. 
     Of course, other offset structures are possible. Other offset structure could use a finished multifiber ferrule that excludes guide pin bores and fits within an offset structure that has the guide pin bores. For example, the finished multifiber ferrule has a generally planar construction that inserts into and attaches to a generally rectangular offset structure having a passageway for receiving the same. Conversely, the offset structure could merely attach to the finished multifiber ferrule about the optical fibers so that one or more guide pins bores are not located on the offset structure. 
     Additionally, other finished multifiber ferrules can have other suitable configurations such as including a plurality of backdraft portions. Illustratively,  FIG. 14  depicts a multifiber ferrule  530  having a plurality of backdraft portions  532 . In this embodiment, the first surfaces (not numbered) of the front end having guide pin bores  534  are, generally speaking, co-planar with a second surface  550  having the openings for optical fiber bores  552 . Thus, the laser beam can cut from either side of finished multifiber ferrule  530 . In other embodiments, second surface  550  need not be co-planar with the first surface as shown. Simply stated, suitable multifiber ferrule assemblies provide optical fibers that extend a suitable distance from the ferrule where the optical fiber bores are located (e.g., the second front surface having the openings for the optical fiber bores) to inhibit interaction with the front of the ferrule during processing of the optical fibers that may cause marking and/or damage. Additionally, the multifiber ferrule assembly presents the processed fiber with an effective fiber height (i.e., short protrusion or the like) for mating with another complimentary fiber optic assembly 
     Although the present invention has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples can perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention and are intended to be covered by the appended claims. It will also be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.