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Author: James Publish Time: 02-09-2025 Origin: Site
Splicing fiber optic cable is an extremely important phase for making dependable, high-speed communication infrastructures. Regardless of the type of fiber network you're deploying, be it for telecom, enterprise data centers, or smart city infrastructure, fusion splicing provides the benefits of low signal loss and long-term sustainability.
In this guide, you will find a chronological description of the fusion splicing process, the principal technical standards, and answers to the real-life questions network engineers and procurement teams may have. Therefore, we will also touch on cost factors, risk management, and best practices in order for you to make the right decisions.
Fusion splicing joins two optical fibers permanently using an electric arc. It creates a continuous path for light signals with minimal reflection and attenuation.
Compared to mechanical splicing:
Lower insertion loss: Typically 0.02 - 0.05 dB
Higher reliability: No mechanical stress points or alignment sleeves
Longer lifespan: Less susceptible to environmental damage
The Telecommunications Industry Association (TIA-568.3-D) notes that fusion splicing can be the product of a welding (thermal fusion) process or another precise fiber-optic splicing technique.
Before you begin, you’ll need:
Tool | Purpose | Key Spec |
Fiber stripper | Removes coating without damaging glass | Adjustable depth (250μm, 900μm) |
Cleaver | Makes perfect perpendicular end-face | Angle < 1° |
Fusion splicer | Aligns and melts fibers | Core alignment, auto-splice mode |
Heat shrink oven | Protects splice with sleeve | Shrinks 60mm sleeve in ~30 sec |
Inspection microscope | Checks cleave quality | 200x magnification |
Alcohol wipes & lint-free swabs | Clean fiber before splicing | Isopropyl alcohol (IPA), 99% purity |
Pro Tip: Always use manufacturer-recommended consumables. Low-quality splice sleeves can lead to 3x higher failure rates over 5 years (source: OFS Fitel reliability report, 2022).
Strip 3–5 cm of the outer jacket using a cable slitter.
Expose the fiber buffer tube. If it’s tight-buffered, strip the 250μm coating carefully.
Avoid putting tension on the fiber. Bending radius should be >30 mm during handling.
Wipe the exposed fiber with IPA-soaked swab.
Do not touch the glass surface. Oils from skin cause weak splices.
Use a precision cleaver.
Hold the fiber straight. A bad cleave (chipped or angled end) causes high loss or splice failure.
Inspect under microscope: flat, mirror-like surface = good.
Open the splicer’s windshields.
Place each fiber in the V-groove, clamps facing up.
Close the covers gently.
Common Mistake: Forcing the fiber into the groove damages the cleave. Let it rest naturally.
Press “Start.” The machine:
Aligns the cores (in core-alignment models)
Preheats to remove moisture
Fires a small arc to fuse the fibers
Process takes 10–20 seconds.
The splicer displays estimated loss (e.g., 0.03 dB).
Acceptable fusion splice loss: ≤0.1 dB per joint (per ITU-T G.652.D).
If loss > 0.15 dB, re-cleave and re-splice.
Slide the splice protector over the joint.
Place in heat oven. Wait for completion tone.
Final protection: strong, flexible, and strain-relieved.
Bend the fiber in a smooth loop, radius ≥30 mm.
Secure with clips. Do not pinch.
Close the closure or cabinet.
Metric | Typical Value | Industry Standard |
Average splice loss | 0.04 dB | ≤0.1 dB |
Return loss | >60 dB | >55 dB |
Tensile strength | >200 g | >100 g after splice |
Long-term reliability | <0.5% failure over 10 years | Based on Telcordia GR-326 |
Core alignment splicers (e.g., Fujikura 70S, INNO View 7) achieve 99% success rate when used correctly. Cheaper cladding alignment units may require 2–3 attempts per splice.
No. Single-mode (SMF) and multimode (MMF) fibers have different core sizes (9μm vs 50/62.5μm). Splicing them causes huge loss (>3 dB) and is not recommended. Use a media converter instead.
Top 3 causes:
Poor cleave (dust, angle, crack)
Dirty fiber (oil, dust)
Misalignment (especially in low-end splicers)
Fix: Clean, re-cleave, and re-splice. Always inspect before loading.
Cost Factor | Estimate |
Labor (on-site) | $15–$25/splice |
Equipment amortized | $3–$8/splice (over 10k splices) |
Consumables (sleeve, alcohol) | $0.50/splice |
Total average | $20–$35/splice |
Buying vs. renting a splicer? If you do >50 splices/month, buying pays off in 6–12 months.
Yes. Even with auto-machines, technique matters. A trained technician makes 30% fewer errors and works 40% faster (data from Corning training program, 2023).
Most manufacturers offer free online courses. Hands-on practice with scrap fiber is essential.
Yes — if protected properly. Use:
Gel-free splice closures (IP68 rated)
UV-resistant sleeves
Proper strain relief
Unprotected splices fail within 2 years in direct sunlight or wet environments.
When sourcing equipment, consider:
High consistency: ≤ 0.02 dB variation within 100 splices
Portability: At least 200 splices per charge for field work
Durability: IP52 rated or better for dust and water resistance
Upgradability: Support for software and firmware updates
Warranty and service: 3-year coverage, local service centers recommended
Best on the market:
Fujikura 70S+: Best for long-haul network builds
INNO View 9: High precision, budget-friendly
Sumitomo Type-81C: Rugged, widely used in utilities
Industry Insight: Over 70% of network outages related to fiber are due to poor splicing or patch panel management — not cable breaks (source: Uptime Institute, 2023).
Skipping inspection: 60% of bad splices come from unclean or poorly cleaved fiber.
Bending too tight: Sharp bends cause microcracks and signal loss.
Rushing the process: Take time. A single bad splice can cost $500+ in troubleshooting later.
Using expired splice sleeves: Old sleeves don’t seal well. Check production date.
All splices inspected and recorded
Loss values documented (use splicer’s memory or app)
Fiber organized in tray with proper bend radius
Closure sealed and labeled
As-built diagram updated
Fusion splicing consists of more than just attaching two fibers; rather, it is a multi-facetted endeavor, which ensures a durable, reliable network. Provision of proper tools, staff with relevant skills, and attentive approach enable practically flawless splices; the difference is in the details.
Irrespective of being a field technician, project manager, or procurement officer, this whole process will be beneficial to you in minimizing errors, controlling costs and most importantly ensuring compliance to industry standards.
Need help choosing a splicer or planning a deployment?
Contact our fiber experts for a free consultation and equipment quote.
James is a technical manager and associate at Zion Communication.
Specializes in Optical Fiber communications, FTTH Solutions,
Fiber optic cables, ADSS cable, and ODN networks.
james@zion-communication.com
+86 13777460328
