Fabrication and filling methods for photonic crystal fibers: a review

Abstract Photonic crystal fibers (PCFs) have garnered significant research interest due to their tunable dispersion and small bending radius, presenting extensive application prospects in various fields, such as telecommunication, medical sensing, laser system, and so on. However, due to the large number of micro- and nanoscale channel structures, PCFs are still limited by the complexity and cost of their manufacturing methods, posing significant challenges for large-scale production and applications. In this work, we focused on the key fabrication methods of photonic crystal fibers (PCFs) and the techniques used to fill their microchannels. We also discussed strategies for selecting specific channels within the fibers, comparing the advantages and the limitations in PCF morphology design. In the end, the advancements in PCF fabrication and filling methods were summarized and the development of large-scale PCF manufacturing solutions was forecasted. This work will contribute to advancing the manufacturing processes of PCFs, promoting broader and more large-scale applications in medicine, chemistry, optics, and so on.