A method of forming a crystalline core/crystalline clad (C4) optical fiber. The method comprises coextruding a cladding mixture of a plasticizer and a binder with a yttrium aluminum garnet (YAG) core. The coextrusion dynamically clads a polycrystalline cladding onto the YAG core to yield a green C4 optical fiber. The C4 optical fiber is then densified, preferably in two steps sintering and hot isostatic pressing. The resulting optical C4 fiber has greater power capacity than a glass fiber labor host.

A tri-layer optical fiber. The fiber has a core which is preferably a single crystal and outer cladding, to reduce signal loss. The cladding process begins with high porosity particles, and is known to introduce porosity in the cladding and at the core/cladding interface. The porosity increases refraction and signal loss. The invention interposes a film layer intermediate the core and cladding. The film layer is sputter coated and preferably of the of same material as the cladding. The film prevents diffusion of the porous cladding into the core, minimizing porosity and improving signal transmission.

A tri-layer optical fiber. The fiber has a core which is preferably a single crystal and outer cladding, to reduce signal loss. The cladding process begins with high porosity particles, and is known to introduce porosity in the cladding and at the core/cladding interface. The porosity increases refraction and signal loss. The invention interposes a film layer intermediate the core and cladding. The film layer is sputter coated and preferably of the of same material as the cladding. The film prevents diffusion of the porous cladding into the core, minimizing porosity and improving signal transmission.