Multi-objective optimization of laser fusion tapered fiber probe fabrication using a response surface methodology

In this study, a multi-objective optimization method based on response surface methodology (RSM) is proposed for precision fabrication of tapered fiber probes. We systematically decouple the effects of process parameters on the tip diameter and taper angle of the probes through experimental design. A Plackett–Burman (P-B) screening identified four dominant control factors with significance ranking: laser power > feeding speed > acceleration > acceleration duration. The Box-Behnken design (BBD) experiment established robust predictive models for tip diameter (R 2 =0.9127) and taper angle (R 2 =0.9211), enabling simultaneous optimization of conflicting geometric targets. Optimized parameters reduced fabrication errors to sub-7% with ≥17% accuracy improvement. This method effectively transforms empirical craftsmanship into quantifiable engineering processes and provides scientifically rigorous insights into parameter optimization during the fabrication of fiber micro-structured devices.