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Why fusion splicing is the best method

OSA - Splicing machine for fusion splice a fiber optic cable

Fusion splicing has been around for several decades, and it’s a trusted method for permanently fusing together the ends of two optical fibres to achieve a specific length or to repair a broken fibre link.

As fibre deployment continues to grow, fusion splicing is crossing into the enterprise infrastructure environment and it’s more critical now than ever to understand best practices around fusion splicing.

We break down why fusion splicing is the best method, as well as highlight important stages and processes involved in fusion splicing.

We also offer some important considerations when starting the fusion splicing process to achieve the best results.

OSA - Wire connection with Fiber Optic Fusion Splicing machine

What is fusion splicing?

Fusion splicing is the process of welding the ends of two optical fibres together using an electrical arc. The arc is precisely applied to join the two fibres together so that light passes through the fibres correctly, instead of scattered or reflected back by the splice.

Splicing a fibre optic cable requires added protection of the splice. By using a heat shrink which allows the splice and region surrounding it to be stronger than the original fibre, this is an effective method of adding secure protection.

Splicing involves a three-stage process, and it’s vital to understand each stage in order to evaluate why fusion splicing is the best method.

Cable preparation

Preparation is the first stage of your fusion splicing process. Fusion splicing requires two pieces of bare fibre to be correctly cleaned and prepared. Naturally, cable preparation is essential.

Part of the preparation stage involves removing the fibre cable jacket that protects the fibres from exposure to each individual fibre strand. Once the jacket is removed, you can begin stripping the fibre polymer coating with fibre optic strippers.

The next step is to clean the fibres with a lint-free wipe or cloth and some isopropyl alcohol until they are clean. It’s important that your fibres are clean as only then can you cleave the fibre properly.

OSA - Fiber optic cable splice machine

Fusion splicing

Once you’ve finished preparing your fibres, place them into the alignment fusion splicer facing towards each other, where they are visible and magnified on-screen. Your fusion splicer can automatically control splicing your fibre optic cable.

The fibre is then cleaved with a specialised tool called a fibre cleaver. There are two types of fibre cleavers: a high precision fibre cleaver for single mode applications and a field cleaver for multimode applications.

The fibres are then laterally aligned and moved together where they are gently melted by an electric arc and permanently joined to precision accuracy. This may involve rotating the fibres in polarisation maintaining fibre splicings.

Sealing and protecting

The insertion loss of the fibre is estimated based on the fusion quality and dimensions. The fusion is then pull proof tested when opening the fusion splicer cover.

Once the fibres are accurately connected, the fusion splice joint is then protected with a heat shrink tube with a steel strength member inside to form a solid and reliable fibre joint.

OSA - Fusion splicing

Fusion splicing advantages

Fibre fusion splicing offers long-term reliability, as well as a fast and inexpensive process. But that’s not all the advantages that fusion splicing brings to the table. With many different applications, fusion splicing has benefits including:

  • Compact use
  • Low insertion loss and provides better performance
  • Low back reflection
  • High mechanical strength
  • Permanent application
  • Withstands extreme high temperature changes
  • Prevents dust and other contaminants from entering the optical path
  • Quick and worry-free
OSA - Fiber Optic Cable Connection Internet signal

Important considerations for fusion splicing

While fusion splicing is optimal for certain applications and situations, there are some factors to consider. First and foremost, fusion splicing requires a fusion splicer. If you’re going to purchase a fusion splicer, make sure that you’ll be doing enough splicing to get your return on investment. Renting a splice machine is also an option if you’re not planning to do a lot of splicing.

Another cost to consider is the cleaver. Performance of a splice is highly dependent on the quality of the cleave, so a high precision cleaver is recommended. If you are doing any type of fibre field termination such as mechanical crimp or epoxy-polish, you likely already have a precision cleaver.

Fusion splicing also requires a good, solid work space. And when using splice-on pigtails, you want to be careful to properly manage your splices and slack within splice trays to prevent exceeding the bend radius of the fibre.

OSA -Sumitomo-Fusion-Splicer-Type-72C

Improve splicing performance with OSA’s fusion splicers

At OSA, our tools and supplies are of superior quality, ensuring high performance each and every time for our client’s job, regardless of size.

We carry world class, durable fusion splicers with industry-leading features as well as an extensive range of strippers and cleavers. All of our tools and supplies are held in stock at our Australia-wide network of fully-stocked warehouses.

At OSA, we also work closely with Sumitomo to ensure we deliver the very best optical fibre fusion splicers and fibre optic solutions to our customers across a range of market verticals.

Sumitomo’s entire industry-leading range of splicers offers quick termination and new standards in heater shrink time.

As an industry leader in optical fibre and connectivity solutions, our supply of Sumitomo’s fusion splicers delivers reliability, flexibility and unbelievable performance.

Contact us today for more information.

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