The process of splicing fiber is a complex one, but there are two common ways to accomplish this. These are fusion splicing and mechanical splicing.

Both methods have their benefits and drawbacks. However, it is important to choose the correct technique for your long-term goals.

Preparation

Fusion splicing is a preferred method of joining fiber optic cable since it produces an end to end connection that is strong and attenuation free. However, this technique is not appropriate for all applications.

When splicing fiber optic cables, the first step is to prepare both ends of the optical fiber for fusion. This process involves removing the protective polymer coatings from both ends of the optical fiber. This is done by using a mechanical stripper or a thermal stripper.

Next, the fiber must be cleaned to remove any dirt, debris, or contaminates that may interfere with the fusion splicing process. This is best done using a 99.9% isopropyl alcohol wipe and then a different type of cleaning solution. Once the fiber is clean, it is ready to be inserted into the splicer.

Before splicing begins, the splicer must be aligned so that the fiber ends are perfectly centered on the electrodes of the splicer. Once the fiber ends are properly aligned, the splicer can heat them together to fuse them.

Alignment can be manual or automatic depending on the type of splicer you have. When using an automated splicer, the operator must set the splicing program to provide desired results.

After the splicing is completed, you should place a heat shrink sleeve around the fusion area to protect it from damage. This will help prevent any stretching or rough handling that might cause the splice to fail.

To maintain the quality of your splicer, it is important to regularly clean it and follow the manufacturer's instructions. This includes alignment and occasional replacement of the electrodes.

It is also important to keep track of the splice loss results from your splicer as different equipment, fiber types and methods yield varying splice loss results. A OTDR can be used to verify these results and ensure that your splices are performing at or below splice loss specifications.

The splice loss measurement of your splicer can be used to verify the spliced ends meet the required splice loss specifications for your network. This will help you to make the right decisions about your splicing needs.

Alignment

Alignment is a critical step in the process of fusing fibers together. This is because the optical fibers will be subject to bending and tensile forces during fusion and can break if not aligned properly.

There are several different alignment technologies used in fusion splicers. Some are passive and do not move the spliced fibers in the x and y axes but rather just move them in the z axis (single-axis). Others, like the cladding-aligned machine above, use a camera to align the fibers based on the cladding of the fibers.

In this method, the splicing ends are placed in the V-groove and then the camera adjusts the v-groove to make sure that the cladding is aligned with each other. Then two motors are used to advance the fibers for electrode discharge welding.

Other types of fusion splicers use a process called “core alignment” to line up the fibers. These machines use multiple video cameras and power-feedback methods to image a pair of corresponding cores in each fiber, and then align the fiber cladding around them.

A splicer like the Fujikura FSM-100P+ used by Zheng, for example, uses video and pattern-matching algorithms to align a pair of cladding-bound fiber cores. Once the cores are finely aligned, they are heat-spliced together.

The key is to use a core-aligned machine with high-precision cleavers. These cleavers are able to cleave the fibers in a way that ensures that they don't break during the splicing process.

Some Fusion Splicer also have a prefuse cycle to remove dirt from the fiber ends before fusing. This can reduce the amount of dust and dirt in the spliced fibers, reducing the likelihood of damage.

Once the splicing is complete, the splicer will inspect the splice to estimate the loss and then tell the operator whether or not the splice is good for use. If the splice is not good for use, it will need to be remade.

Before a splicer is used in the field or within a Lab/OEM environment, it needs to be cleaned regularly and its electrodes aligned. It should also be serviced occasionally, and replacement parts should be used as needed.

Fusion

A fusion splicer is a device that joins two optical fibers together to form one new cable. It can be used in a number of applications, including FTTX, buried splice closures, data center panels and building distribution boxes.

The fusion process starts with proper preparation and alignment of the two cleaved fiber ends. This includes removing the coatings on both ends and exposing the bare glass. Then both ends are cleaved to achieve a 90 degree angle on each fiber end-face, resulting in less optical loss. The cleave length varies with each splicer, so refer to the operating manual for that specific model.

Once the spliced fiber ends are aligned, they are heated in an electric arc to fuse the two end faces. This process may be done manually, but many splicers feature an automatic arc cycle that heats the two ends together at a controlled rate.

Next, the Splicing Machine will perform an inspection program that evaluates the splice joint for quality. This usually involves sending a testing optical ray through the spliced fibers to determine the amount of loss. The machine then reports this to the operator and indicates if the splice must be remade.

The splicing process generally requires some training and practice to ensure that the technician is proficient in the use of the equipment. It also entails learning how to strip and clean the spliced fiber.

Preparing the fiber before insertion into the splicer is essential to achieving a quality splice and to ensure that no dirt is left behind on the spliced ends. Dirt or other impurities on the spliced ends can interfere with the fusion process and cause weak splices or poor tensile strength of the spliced joint.

Cleaning is a top priority, and most splicers feature a precautionary cleaning step. During the cleaning process, the splicer generates a small spark between the cleaved ends to burn away any remaining dust or moisture that may be present.

Once a quality splice is achieved, the spliced fiber ends are protected with a heat shrinkable protective sleeve. This is an important step because it allows the spliced fiber to be wrapped securely and prevents any water damage.

Closure

Fiber optic splicing is a very important process in the transmission of optical data. This is because it combines fibers to create a cable that can transmit data at a high speed.

The splicing process is performed using a fusion splicer, which uses an electrical arc to melt the end of two fibers and fuse them together. This process produces a high-quality splice with low loss values.

To perform a fusion splice, you need to have the correct tools and equipment for the job. This includes a splice tray and a splice closure. The splice closure will house the spliced cable until it is ready to be installed.

A splice closure is made up of a number of components that work together to protect the cable and ensure it functions properly. These components include the splice tray, the splice closure and a splice holder.

After splicing, the cable will be placed in a splice closure and will be sealed to prevent moisture damage. The splice closure will also contain a splice holder, which is where the spliced fibers will be stored until it is time to install them.

Splices are a critical component of the fiber infrastructure, which means they must be handled carefully to ensure their performance. If a splice is not properly done, it can cause a loss of performance that will affect the quality and reliability of the cable.

There are a few signs to look for that may indicate that a splice isn’t done correctly. These can include poor alignment of the wires on their guides, a cleaved fiber that has some residual plastic cover or dirt on its end and a splice that doesn’t register on an optical time domain reflector (OTDR).

If you see any of these issues in your splice, you should redo it to ensure it is working properly. If you don’t, your fibers could be damaged and the installation will not function properly.

The splice closure is the final step in the fiber splicing process. After it is sealed, the cable will be placed into a designated location to finish the installation.