Systems and methods for forming 3D plastic parts that are cost effective in low volume, have excellent fit and finish, and use many components from 2D construction are disclosed. The systems and methods involve selecting a design and modelling the design. The design comprises 2D and 3D components of plastic parts. A 3D forming buck corresponding to the 3D component is manufactured. At least one of a 2D part and the 3D forming buck may be heated. The 2D part may be loaded onto the 3D forming buck for a predefined period of time. The 3D part formed after the loading may be separated from the 3D forming buck. The 3D part is the 2D part generally having taken the shape of the 3D forming buck. The 3D part may be cooled to obtain an end product.

Systems and methods for forming 3D plastic parts that are cost effective in low volume, have excellent fit and finish, and use many components from 2D construction are disclosed. The systems and methods involve selecting a design and modelling the design. The design comprises 2D and 3D components of plastic parts. A 3D forming buck corresponding to the 3D component is manufactured. At least one of a 2D part and the 3D forming buck may be heated. The 2D part may be loaded onto the 3D forming buck for a predefined period of time. The 3D part formed after the loading may be separated from the 3D forming buck. The 3D part is the 2D part generally having taken the shape of the 3D forming buck. The 3D part may be cooled to obtain an end product.

In some implementations, a fiber processing machine may receive an optical assembly comprising an input fiber, an output fiber, and a graded index fiber spliced between the input fiber and the output fiber, wherein the graded index fiber has a pitch length and a processed length. A light source may deliver input light into an input end of the input fiber while one or more components monitor output light at an output end of the output fiber. The fiber processing machine may alter a core diameter and the processed length of the graded index fiber until one or more measurements of the output light at the output end of the output fiber indicate that the output light is a perfect image of the input light.

In some implementations, a fiber processing machine may receive an optical assembly comprising an input fiber, an output fiber, and a graded index fiber spliced between the input fiber and the output fiber, wherein the graded index fiber has a pitch length and a processed length. A light source may deliver input light into an input end of the input fiber while one or more components monitor output light at an output end of the output fiber. The fiber processing machine may alter a core diameter and the processed length of the graded index fiber until one or more measurements of the output light at the output end of the output fiber indicate that the output light is a perfect image of the input light.

The invention discloses a draw tower (100) comprising a top end zone (108) to insert a preform along with fluid and the preform is melted into an optical fiber (106) that exits from a bottom end zone (110). The draw tower (100) includes a plurality of air knives (112) distorting optical fiber path such that partially uncooled optical fiber deviates from a vertical path to a bended path wherein the plurality of air knives (112) is a plurality of openings arranged such that to cause distortion on the vertical path of the optical fiber (106) in the draw tower (100) and the plurality of openings is a combination of one or more of a suction and pumping of the fluid. Further, the bended path length is greater than a vertical path length and is defined by laminar flow for at least 70% of the bended path length.

The invention discloses a draw tower (100) comprising a top end zone (108) to insert a preform along with fluid and the preform is melted into an optical fiber (106) that exits from a bottom end zone (110). The draw tower (100) includes a plurality of air knives (112) distorting optical fiber path such that partially uncooled optical fiber deviates from a vertical path to a bended path wherein the plurality of air knives (112) is a plurality of openings arranged such that to cause distortion on the vertical path of the optical fiber (106) in the draw tower (100) and the plurality of openings is a combination of one or more of a suction and pumping of the fluid. Further, the bended path length is greater than a vertical path length and is defined by laminar flow for at least 70% of the bended path length.