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To compliment the development of the single channel small form factor size 16 optical Expanded Beam (EB) pin and socket contacts, we have explored the possibility of designing a multi-fiber high density lensed termini (HDLT). This paper describes the design efforts of an insert containing two ferrules accommodating a total of 24 fibers and mountable into a size 8 Quadrax cavity of a 38999 style connector. To take advantage of the expanded beam concept and to keep the design cost effective, the ferrules are molded with a 12 fiber v-groove array positioned behind integral lenses. Originally, the ferrules were designed for the relative benign environment of datacom applications. Therefore, in order to accommodate the broader operational environment of arospace applications which includes mechanical vibration, thermal cycling and high humidity exposure a suitable epoxy had to be identified. Design details, proposed solution, and initial test results are discussed.

For most data and telecom fiber optic applications the physical contact (PC) concept is preferred for all indoor and even some outdoor applications. But when these connectors are subjected to a harsh environment, the performance of standard PC connectors has proven unreliable in many applications due to their sensitivity to contamination. The subject for this paper is the design of a small form factor expanded beam (EB) fiber optic contact pair suited for operation in a challenging environment. The contacts conform to the dimensional envelope of MIL-PRF-29504/4/5D and employ a separable lens unit design which provides the option for field-installable terminations. The EB concept typically exhibits a higher loss than the PC connection, but preliminary results of the new design indicate that the size 16 termini pair using 1.25mm lenses and ferrules yields a very good loss performance.