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Simple Fabrication of Fiber Optic Pigtails

Fiber and communications infrastructure knowledge brief Published 16 Apr 2024

Prepared for preliminary research by the ROGER FIBRE knowledge desk. Confirm optical interfaces, port or core capacity, electrical input and output, enclosure protection, thermal design and installation limits against current standards and product documentation.

Fiber optic pigtails are made by splicing a factory-terminated connector to a bare fiber using either fusion or mechanical splicing, ensuring low-loss, reliable connections.

Understanding Fiber Optic Pigtails

A fiber optic pigtail is a short optical fiber with a factory-installed connector on one end and a bare fiber on the other. The connector end plugs into equipment or patch panels, while the bare end is spliced to the incoming fiber cable in the field. Pigtails are preferred over field-terminated connectors because they provide factory-grade quality, lower insertion loss, and higher reliability.

Types of PigtailsSingle-mode pigtails: 9/125µm core, used for long-distance telecom and high-bandwidth applications. Multimode pigtails: 50/125µm or 62. 5/125µm core, suitable for short-distance networks like campus or building installations.

Connector types: LC, SC, ST, FC, MU, E2000, MPO, depending on network requirements. Methods for Making Pigtails1.

Fusion Splicing

Fusion splicing is the most common method for permanent, low-loss connections: Prepare the fibers: Strip the outer jacket and buffer from both the pigtail and incoming fiber using fiber strippers. Cleave the fibers: Use a high-precision cleaver to create a flat, 90-degree end face. Clean the fibers: Wipe with lint-free wipes and 99% isopropyl alcohol to remove debris and oils.

Splice the fibers: Place the fibers in a fusion splicer, which uses an electric arc to weld them together, forming a continuous optical path. Protect the splice: Slide a heat-shrink splice protection sleeve over the joint and cure it in the splicer's oven to provide mechanical strength and environmental protection. 2.

Mechanical Splicing

Mechanical splicing is a quicker, less permanent alternative: Prepare and cleave fibers: Similar to fusion splicing, strip and cleave both fibers. Align fibers in a mechanical splice: Insert the fibers into a precision alignment sleeve filled with index-matching gel to minimize signal loss. Secure the splice: Lock the fibers in place using the mechanical splice housing, which holds them in precise alignment.

Tools Required

Fusion splicer or mechanical splice kitFiber strippersHigh-precision cleaverLint-free wipes and isopropyl alcoholHeat-shrink splice protection sleeves (for fusion splicing)Best PracticesAlways work in a clean environment to prevent contamination. Ensure fibers are properly cleaved and cleaned before splicing. Use factory-terminated connectors to maximize performance.

Test the splice with an optical power meter or OTDR to verify low insertion loss and minimal back reflection. By following these methods, technicians can create reliable, low-loss fiber optic pigtails suitable for data centers, FTTH deployments, and other high-performance optical networks.

Simple Fabrication of Fiber Optic Pigtails - ROGER FIBRE ATELIER [PDF]

Simple Fabrication of Fiber Optic Pigtails

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Technical note

This reference is intended for preliminary fiber and communications infrastructure research. Optical interface, fiber type, port or core capacity, electrical input and output, enclosure protection, cooling, installation limits and applicable standards must be verified for the specific project.

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