How to make a connector for armored optical cable

To make a connector for armored optical cable, carefully strip the armor and protective layers, clean and cleave the fiber, then terminate using a compatible connector or fusion splice while following safety and optical testing procedures.

Understanding Armored Optical Cable

Armored optical cables have a metal armor layer (stainless steel or corrugated steel) between the outer sheath and the fiber core, providing protection against crushing, moisture, rodents, and mechanical stress . They may also include an inner protective layer and aramid (Kevlar) strength members for additional tensile strength . This structure makes them stiffer and heavier than standard fiber, requiring careful handling during termination .

Tools and Preparation

Before connectorization, gather the following tools:

• Fiber strippers and cutters suitable for armored cables
• Kevlar scissors for strength members
• Fiber cleaver
• Cleaning kit (lint-free wipes, alcohol)
• Microscope or inspection tool
• Connector kit (LC, SC, or mechanical splice)
• Fusion splicer if using fusion splicing Inspect the cable for damage, confirm fiber type (single-mode or multimode), and plan the bend radius and routing path to avoid stress on the fiber .

Step-by-Step Connectorization

1. Cut the Cable: Use a fiber cable cutter to cut the armored cable to the desired length, adjusting blade depth to match armor thickness .
2. Strip the Outer Jacket and Armor: Carefully remove the outer sheath and metal armor using appropriate stripping tools. Wear gloves to avoid injury from sharp metal edges .
3. Handle Strength Members: Cut Kevlar or aramid fibers with specialized scissors to prevent fraying .
4. Expose and Clean the Fiber: Strip the inner protective layer to expose the bare fiber. Clean the fiber end thoroughly with alcohol and lint-free wipes, inspecting under a microscope to ensure no debris or scratches .
5. Cleave the Fiber: Use a precision cleaver to create a flat, smooth fiber end for optimal light transmission .
6. Terminate the Connector:
   • Mechanical Connector: Insert the cleaved fiber into a mechanical splice or quick-connect connector, ensuring precise alignment for minimal insertion loss (~0.3 dB typical), .
   • Fusion Splice: Place the fiber ends in a fusion splicer, align, and fuse them using heat or electric arc. Protect the splice with a fusion splice protector .
7. Test the Connection: Perform optical testing using an OTDR, power meter, or visual fault locator to verify continuity, insertion loss, and return loss .

Safety and Best Practices

• Follow the manufacturer's recommended minimum bend radius (typically 20–30 mm or more) to prevent fiber damage .
• Avoid pulling or twisting the fiber; armored cables are heavy and stiff .
• If the armor is conductive, ensure proper grounding according to local safety standards .
• Always wear gloves and eye protection when cutting metal armor . By following these steps, you can create a reliable, low-loss connection for armored optical cables suitable for harsh or industrial environments, ensuring long-term network performance and durability .