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In this work, a novel infinity 3D printing technique is explored to fabricatecontinuous multi-meter-long low-loss near-zero dispersion suspended-corepolypropylene fibers for application in terahertz (THz) communications.Particular attention is paid to process parameter optimization for 3D printingwith low-loss polypropylene plastic. Three microstructured THz fibers were 3Dprinted using the standard and infinity 3D printers, and an in-depththeoretical and experimental comparison between the fibers were carried out.Transmission losses (by power) of 4.79 dB/m, 17.34 dB/m and 11.13 dB/m areexperimentally demonstrated for the three fibers operating at 128 GHz. Signaltransmission with BER far below the forward error correction limit (10-3) forthe corresponding three fiber types of lengths of 2 m, 0.75 m and 1.6 m areobserved, and an error-free transmission is realized at the bit rates up to 5.2Gbps. THz imaging of the fiber near-field is used to visualize modaldistributions and study optimal fiber excitation conditions. The ability ofshielding the fundamental mode from the environment, mechanical robustness andease of handling of thus developed effectively single-mode high opticalperformance fibers make them excellent candidates for upcoming fiber-assistedTHz communications. Additionally, novel fused deposition modeling (FDM)-basedinfinity printing technique allows continuous fabrication of unlimited inlength fibers of complex transverse geometries using advanced thermoplasticcomposites, which, in our opinion, is poised to become a key fabricationtechnique for advanced terahertz fiber manufacturing.

Microstructured fiber links for THz communications and their fabrication using infinity printing