Fiber Array Unit Polishing Workflow On NOVA For Repeatable FAU Processing

Fiber Array Units, or FAUs, require careful handling, controlled polishing, and accurate inspection to achieve consistent endface quality. From initial loading through final inspection, each stage of the process plays an important role in creating a repeatable polishing workflow. KrellTech’s NOVA™ system is designed to support that process by giving operators a structured way to load, process, monitor, clean, and inspect Fiber Array Units with greater control.

In this workflow demonstration, KrellTech shows how a Fiber Array Unit is loaded into a carrier and then placed into the NOVA workholder for processing. Proper fixturing is an important part of photonic component polishing because component stability, alignment, and handling can all influence the final result. By securely supporting the FAU throughout the polishing sequence, operators can create a more controlled and repeatable process from one component to the next.

Once the component is loaded, the NOVA system can be programmed for the desired polishing procedure. This gives operators the ability to follow a defined process and maintain better control over each polishing stage. For Fiber Array Units and other photonic components, a programmable system can be especially valuable during process development, prototyping, and production, where repeatability and process consistency are critical.

The workflow also includes measuring and tracking material removal during processing. Material removal tracking is an important part of precision photonic component polishing because it gives operators better visibility into how much material has been removed at each stage. This can help support process refinement, improve confidence in the workflow, and make it easier to develop repeatable polishing procedures for demanding applications.

As the FAU moves through the process, operators may switch polishing films and discs to match the requirements of each polishing step. Each stage contributes to the final surface quality, geometry, and endface condition. KrellTech supports this workflow with polishing consumables designed for a wide range of photonic component applications, helping customers maintain process continuity while selecting the right materials for their process.

Before final inspection, the component is cleaned using KrellTech’s SkyBrite™ wipes. Cleaning is an important step because it helps prepare the component for accurate inspection and allows operators to better evaluate the polished surface. This can be useful both between polishing stages and when reviewing the final result.

The last stage of the workflow is inspection. After polishing and cleaning, the Fiber Array Unit is inspected to evaluate the endface and confirm the outcome of the process. Inspection helps operators understand the results of each polishing stage and determine whether the component meets the desired requirements or needs additional processing.

Although this example focuses on a Fiber Array Unit, the same general workflow principles apply to many other photonic components. KrellTech systems support polishing, shaping, and inspection for fiber arrays, waveguides, PICs, bare fibers, fiber optic connectors, and other precision optical components. The NOVA platform gives users a flexible system for controlled polishing, material removal tracking, consumable changes, cleaning, and inspection across a range of photonic applications.

For customers working with FAUs in research, prototyping, or production, KrellTech’s NOVA workflow demonstrates how controlled fixturing, programmable processing, material removal tracking, and final inspection can come together in a more repeatable photonic component polishing process.

Watch the full fiber array unit (FAU) polishing workflow overview video.