We propose and demonstrate a novel in-fiber Mach-Zehnder interferometer (MZI), using a femtosecond (FS) laser to inscribe two parallel straight waveguides along both sides of the core-cladding boundary of an optical fiber. Both simulations and experiments demonstrated that constructing a second straight waveguide (WG2) on the opposite side of the fiber core significantly enhances the mode coupling efficiency in fiber, resulting in ultra-sensitive small twist-angle torsion measurement by intensity interrogation. By finely adjusting the waveguide spacing between the WG2 and the fiber core during the FS fabrication process, a large tuning range of ∼ 200 nm for the designable interference wavelength with maximal fringe contrast has been achieved. Through comparative experiments, the proposed in-fiber MZI performs ultra-sensitivity with 17417.92 dB/(rad/mm) over small twist angles from −10° to 0° for the sample “WG1-4/WG2-4” and 19480.57 dB/(rad/mm) over small twist angles from 0° to 10° for the sample “WG1-4/WG2-6”. Besides, the device is insensitive to temperature and strain. The exhibited advantages of high sensitivity, high reproducibility, and low crosstalks promote the proposed in-fiber MZI to be applied in future industrial engineering monitoring and intelligent health monitoring.
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