Functional Coatings for Fiber Bragg Gratings: A Critical Review of Deposition Techniques for Embedded and Harsh-Environment Applications

Fiber Bragg Grating (FBG) sensors facilitate compact, multiplexed, and electromagnetic interference-immune monitoring in embedded and harsh environments. The removal of the polymer jacket, a measure taken to withstand elevated temperatures or facilitate integration, exposes the fragile glass. This underscores the necessity of functional coatings, which are critical for enhancing durability, calibrating sensitivity, and improving compatibility with host materials. This review methodically compares coating materials and deposition routes for FBGs, encompassing a range of techniques including top-down physical-vapor deposition (sputtering, thermal/e-beam evaporation, cathodic arc), bottom-up chemical vapor deposition (CVD)/atomic layer deposition (ALD), wet-chemical methods (sensitization/activation, electroless plating (EL), electrodeposition (ED)), fusion-based processes (casting and melt coating), and hybrid stacks (e.g., physical vapor deposition (PVD) seed→ electrodeposition; gradient interlayers). The consolidation of surface-preparation best practices and quantitative trends reveals a comprehensive understanding of the inter-relationships between coating material/stack, thickness/microstructure, adhesion, and sensitivity across a range of temperatures, extending from approximately 300 K to cryogenic regimes. Practical process windows and design rules are distilled to guide method selection and reliable operation across cryogenic and high-temperature regimes.