LOW COST MOLDED OPTICAL PROBE WITH ASTIGMATIC CORRECTION, FIBER PORT, LOW BACK REFLECTION, AND HIGHLY REPRODUCIBLE IN MANUFACTURING QUANTITIES

1 . A molded optical probe, comprising:

a fiber receiving portion defining a groove defined along a longitudinal axis for receiving an optical fiber;

a spacer portion having a spacer portion surface non-orthogonal to the longitudinal axis of the groove, the spacer portion surface configured to cooperate with a distal end of the optical fiber;

a prism portion positioned adjacent the spacer portion and having a prism surface non-parallel to the spacer portion surface and non-orthogonal to the longitudinal axis and configured to reflect light transmit through the optical fiber off perpendicular to the longitudinal axis; and

a lens portion positioned adjacent the prism portion and having a lens surface configured to focus light received through the optical fiber.

2 . The molded optical probe of claim 1 , wherein the fiber receiving portion, comprises:

a first section configured to receive an outer insulator containing the optical fiber; and

a second section configured to receive the optical fiber.

3 . The molded optical probe of claim 1 , wherein the molded optical probe is monolithic.

4 . The molded optical probe of claim 1 , wherein an optical axis of the lens portion is tilted 1.5 degrees off axis.

5 . The molded optical probe of claim 1 , wherein the lens surface is coated with an anti-reflective coating.

6 . The molded optical probe of claim 1 , wherein the spacer portion surface of the spacer portion and the distal end of the optical fiber are separated by a set distance to adjust for optical tolerances.

7 . The molded optical probe of claim 6 , wherein the spacer portion surface of the spacer portion includes a compensating pin in contact with the distal end of the optical fiber to separate the first surface from the distal end at the set distance.

8 . The molded optical probe of claim 1 , wherein the spacer portion surface of the spacer portion is manufactured at an angle between −10 degrees and 10 degrees.

9 . The molded optical probe of claim 8 , wherein the spacer portion surface of the spacer portion is manufactured at an angle of 4.00 degrees.

10 . The molded optical probe of claim 1 , wherein the distal end of the optical fiber is manufactured at an angle between 0 degrees and 10 degrees.

11 . The molded optical probe of claim 10 , wherein the distal end of the optical fiber is cleaved at an angle orthogonal to an angle of the spacer portion surface of the spacer portion.

12 . The molded optical probe of claim 1 , wherein the prism surface is at an angle off perpendicular to the longitudinal axis from 2 degrees to 80 degrees.

13 . The molded optical probe of claim 12 , wherein the prism surface is manufactured at an angle of 50.10 degrees.

14 . The molded optical probe of claim 1 , wherein the lens surface is at an angle off perpendicular to the longitudinal axis from −10 degrees to 10 degrees.

15 . The molded optical probe of claim 14 , wherein the lens surface is manufactured at an angle of 1.5 degrees off axis.

16 . A molded optical probe with astigmatic correction, fiber port, and low back reflection, comprising:

a fiber receiving portion defining a groove defined along a longitudinal axis for receiving an optical fiber and an outer insulator, comprising:

a first section configured to receive the outer insulator containing the optical fiber; and

a second section configured to receive the optical fiber;

a spacer portion having a spacer portion surface non-orthogonal to the longitudinal axis of the groove, the spacer portion surface configured to cooperate with a distal end of the optical fiber;

a prism portion positioned adjacent the spacer portion and having a prism surface non-parallel to the spacer portion surface and non-orthogonal to the longitudinal axis and configured to reflect light transmit through the optical fiber off perpendicular to the longitudinal axis; and

a lens portion positioned adjacent the prism portion and having a lens surface configured to focus light received through the optical fiber onto a surface,

wherein the molded optical probe is monolithic.

17 . The molded optical probe of claim 16 , wherein the spacer portion surface of the spacer portion is manufactured at an angle between −10 degrees and 10 degrees.

18 . The molded optical probe of claim 16 , wherein the distal end of the optical fiber is manufactured at an angle between 0 degrees and 10 degrees.

19 . The molded optical probe of claim 16 , wherein the prism surface is at an angle off perpendicular to the longitudinal axis from 2 degrees to 80 degrees.

20 . The molded optical probe of claim 16 , wherein the lens surface is at an angle off perpendicular to the longitudinal axis from −10 degrees to 10 degrees.

21 . A method for manufacturing a molded optical probe according to claim 1 , comprising:

molding the optical probe;

stripping the outer insulator to expose the optical fiber;

spacing the distal end of the optical fiber from the spacer portion surface at a set distance to adjust for optical tolerances; and

attaching the optical fiber and the insulator to the molded optical probe using an optical adhesive having a specified index of refraction.

22 . The method of claim 21 , wherein the molding is performed by an injection molding process or a stamp molding process.

23 . A method for manufacturing a molded optical probe including a fiber receiving portion, a spacer portion having a spacer portion surface non-orthogonal to the longitudinal axis of the fiber receiving portion, the spacer portion surface configured to cooperate with a distal end of an optical fiber, a prism portion positioned adjacent the spacer portion and having a prism surface non-parallel to the spacer portion surface and non-orthogonal to the longitudinal axis and configured to reflect light transmit through the optical fiber off perpendicular to the longitudinal axis, and a lens portion positioned adjacent the prism portion and having a lens surface configured to focus light received through the optical fiber, comprising:

cleaving the distal end of the optical fiber;

positioning the optical fiber into an injection mold; and

injection molding the molded optical probe about the optical fiber.