High Power Fusion Splicing
Special requirements call for special technologies — for example, in industrial and aerospace applications
About Fusion Splicing
Today, fusion splicing is the standard method for connecting optical fibers. The splicing device generates an electric arc (technically a glow discharge) that heats the quartz glass at the fiber ends to a temperature of around 1,500 °C, causing it to melt. The ends are then pressed together with high precision, creating a homogeneous structure that enables near-lossless light transmission with minimal back reflection. High-quality splices typically have optical losses of less than 0.1 dB.
Standard Procedure: High Optical Performance
In fixed network installations or indoor applications, mechanical stresses are low, and the main focus is on optical performance. Splicing is typically performed on site using small, portable devices. In the standard procedure, there is a clear focus on efficiency and on minimizing signal loss. Mechanical stability is therefore not a major concern.
High Demands
Demanding applications such as subsea installations, industrial facilities, critical infrastructure, and aerospace place significantly higher demands on fiber optic connections. These connections must be able to withstand high tensile forces of 20–30 N or more, continuous water pressure of up to 1,000 bar, as well as strong vibrations and temperature fluctuations between –40 °C and +85 °C. These high-strength splice connections require precise process control, modern splicing technology, and highly qualified specialists.
Technology for Precision
Manufacturers have developed processes that enable exceptionally precise fiber alignment and allow the arc parameters to be adapted to different fiber types. For example, automated image processing is used to ensure consistently high splice quality. Many devices also feature integrated testing and monitoring functions, such as tensile testing or high-resolution attenuation analysis. As a result, faulty splices can be detected at an early stage and corrected in a targeted manner.
Click here
Technical Solutions
Optimized Alignment in Six Axes: Cameras capture the fiber ends from different angles. Image processing software analyzes these images and determines the position, angle, and rotational alignment of the fibers. Using this method, the system ensures that the fiber cores are optimally positioned relative to one another, even when working with multicore or specialty fibers.
Adjustment of Arc Parameters: Different types of fiber optic fibers require different amounts of heat during splicing. Modern fusion splicers therefore automatically adjust the current, arc duration, and arc profile to match the specific fiber type. The glass is heated evenly while avoiding damage to sensitive structures.
Mechanical Strength: In demanding applications, splice connections must meet the highest mechanical requirements. Modern fusion splicers increase splice strength through precise process control and controlled heat input, while the optical quality of the connections remains unaffected. The result is durable splices that can withstand high tensile forces, vibrations, and extreme environmental conditions.
Robust Design: A rugged housing, precise mechanics, and stable optics ensure that the devices operate with maximum precision, even in dusty, humid, or highly vibrating environments, or when exposed to extreme temperature fluctuations. This enables reliable and precise splicing both in the field and in industrial environments.
Fields of Application
Subsea Installations
Submarine cables must withstand extreme environmental conditions, and maintenance is costly. High-strength fusion splices ensure permanently stable connections that guarantee reliable, low-loss data transmission even under high tensile forces, strong water pressure, and humidity.
Manufacturing
In harsh production environments, mechanical stress, vibrations, and temperature fluctuations often lead to malfunctions and operational failures. High-strength fusion splices create stable connections that retain their mechanical and optical quality even during continuous operation.
Critical Infrastructure
Reliable signal transmission is essential for energy, transport, and communications networks. Robust fusion splices reduce the risk of mechanical failures, even with long maintenance intervals and extreme environmental conditions.
Aerospace
In aerospace applications, fiber optic connections must withstand extreme mechanical and thermal stresses and are difficult to repair. High-strength fusion splices offer mechanical stability and low attenuation, ensuring the long-term functionality and safety of complex optical systems.
Contact and Consulting
We find the right solution
Are you planning to use a splicing system for your application? Our experts will assist you in selecting.
LASER COMPONENTS Germany GmbH
Our Products
Core-aligning splicers for fibers with a diameter of up to 1200 µm.
Cladding-centered fiber splicer for rollable ribbons and ribbons of up to 12 fibers. The robust device is particularly suitable for outdoor use.
Core-aligned and cladding-aligned optical fiber splicing is carried out using three-axis splicers.
Fully-automated V-groove splicers are used in simple, cladding-aligned splicing tasks.
Read More
LASER COMPONENTS Germany - Your competent partner for fiber technologies, optical and optoelectronic components in Germany.
Welcome to LASER COMPONENTS Germany GmbH, your expert for photonics components. Each product in our wide range
of fiber technologies, detectors, laser diodes, laser modules, optics, and more is worth every Euro (€/EUR). Our
solutions cover all conceivable areas of application: from sensor technology to medical technology.
You can reach us here:
Werner-von-Siemens-Str. 15
82140 Olching
Deutschland
Phone: +49 8142 2864-0
Email: info(at)
