How to make a fiber optic cable filler strip connector

To make a fiber optic cable filler strip connector, carefully strip the cable layers, prepare the fiber, insert it into the connector, secure it, and verify the splice for proper light transmission.

Tools and Materials Needed

• Fiber optic stripper (with multiple grooves for different buffer sizes)
• Kevlar scissors
• Lint-free wipes and isopropyl alcohol
• Mechanical splice connector or epoxy/polish connector
• Visual Fault Locator (VFL) for verification
• Crimping tool or locking nut (depending on connector type)
• Disposal container for fiber scraps

Step-by-Step Procedure

1. Prepare the Cable

• Cut the cable to the desired length using Kevlar scissors.
• Tie a knot near the end to prevent the fiber and strength members from pulling out during stripping ( ).
• Strip the outer jacket carefully using the fiber stripper, removing about 2–4 inches (50–100 mm) depending on connector instructions ( ).
• Cut and bundle the aramid (Kevlar) fibers, then trim them close to the jacket end to expose the 900-micron buffered fiber ( ).

2. Strip the Fiber

• Using the fiber stripper, remove the buffer coating in small increments (1/4–3/8 inch at a time) to avoid stressing or breaking the fiber ( ).
• For multi-layer buffers, strip progressively: first the 900-micron buffer, then the 250-micron buffer if present ( ).
• Clean the bare fiber with a lint-free wipe and alcohol to remove any debris or oils ( ).

3. Insert Fiber into Connector

• Slip the connector's locking nut onto the cable before inserting the fiber ( ).
• Insert the prepared fiber into the mechanical splice section of the connector until it butts against the factory-installed fiber inside the ferrule ( ).
• Close the connector body to clamp the fiber and, if applicable, the cable jacket. For epoxy/polish connectors, follow the epoxy curing and polishing steps as per manufacturer instructions ( ).

4. Secure and Finish

• Screw on the locking nut or crimp the connector body as required ( ).
• Ensure the aramid fibers are properly anchored to provide tensile strength.

5. Verify the Connection

• Use a Visual Fault Locator (VFL) to check for proper light transmission through the connector ( ).
• Inspect for any cracks, scratches, or misalignment that could cause signal loss.

6. Safety and Cleanup

• Dispose of all fiber scraps in a designated container to prevent injury ( ).
• Handle fibers carefully to avoid skin punctures or ingestion hazards. By following these steps, you can create a low-loss, reliable fiber optic cable filler strip connector suitable for both mechanical and epoxy/polish terminations. Proper preparation, careful stripping, and verification are key to ensuring high-quality optical performance.