Toward the fabrication of directly extruded microstructured bioresorbable phosphate glass optical fibre preforms

The steps toward the fabrication of directly-extruded microstructured fibre preforms made of a bioresorbable phosphate glass are herein presented. Microstructured fibres show a wide range of applications, i.e. photonic crystal fibres, large mode area fibres, hollow gas/liquid sensors, etc. Nevertheless, the fabrication of bioresorbable microstructured fibres has not been feasible so far due to a lack of bioresorbable transparent glass and more flexible fibre preform fabrication techniques. A custom developed calcium-phosphate glass has been designed and carefully prepared in our laboratory to be dissolvable in a biological fluid while being optically transparent and suitable for both preform extrusion and fibre drawing. This glass has been characterised both in terms of mechanical and optical properties as well as for dissolution in aqueous medium. Furthermore, the proposed glass is thermally stable, i.e. can be processed both in the extruder and in the drawing tower. Several extrusion experiments have been carried out with different glass preforms’ shapes. Analyses of these preforms by means of Optical Profilometry and Atomic Force Microscopy have been carried out to assess the roughness of the surface of the extrudate. To support the production of an optimized die for the preform extrusion, a simplified laminar flow model simulation has been employed. This model is intended as a tool for a fast and reliable way to catch the complex behaviour of glass flow during each extrusion and can be regarded as an effective design guide for the dies to fulfil specific needs for preform fabrication. After die optimisation, extrusion of a capillary was realised, and a stacking of extruded tubes was drawn to produce a microstructured optical fibre made of bioresorbable phosphate glass. The combination of bioresorbability and fibre microstructure, show a promising pathway toward a new generation of implantable biomedical devices.