Fusion splicing is the process of permanently joining two optical fibers by melting their ends together, typically using an electric arc, although other heat sources like CO₂ lasers or electrically heated wires can also be used . The fiber ends are first stripped of their coatings, cleaved precisely, and aligned either by core alignment or cladding alignment methods. Once aligned, the fibers are fused, creating a joint with very low insertion loss (0.05–0.1 dB) and minimal reflectance, making it ideal for single-mode fibers .
In ODFs, fusion splicing is used to manage high-density fiber connections efficiently. Modern hyperscale ODFs can support 5,000+ fusion splices within a compact footprint, which is more space-efficient than using connectors at scale . Fusion splicing reduces optical loss compared to connectors, which typically have higher insertion loss (0.2–0.5 dB), and provides a more reliable, maintenance-free connection .
After splicing, fibers are protected using heat-shrink sleeves or specialized splice closures. Single-fiber sleeves typically include stainless-steel strength members, while ribbon sleeves accommodate multiple fibers. Closures are designed to withstand environmental stress, moisture, and temperature variations, often meeting standards like Telcordia GR-771-Core and ISO 9001 .
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