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Vytran® Filament Fusion Splicer![]()
LFS4100 Fusion Splicing System VHT1 Transfer Insert Clamp FTAV2 Graphite Filament VHE25 Fiber Holder VHB05 Fiber Holder Top Insert with LED Indent VHF250 Fiber Holder Transfer Bottom Insert Splicing System, Filaments, Inserts, and Accessories All Sold Separately ![]() Please Wait ![]() Applications of the Vytran LFS4100 Filament Fusion Splicer Features
Build Your System
Thorlabs' LFS4100 Vytran® Filament Fusion Splicer for Standard, Large-Diameter, and Specialty Optical Fiber combines filament fusion technology, a high degree of user process control, and simple operation. These properties make this system ideal for volume production in manufacturing environments that demand precise, consistent performance. The splicer is designed to perform high-quality fusion splicing for fibers with claddings from Ø125 µm to Ø1.25 mm. An ultrasonic cleaner for preparing fibers for splicing can be purchased separately below. The LFS4100 system consists of a filament-based heater, a microscopic high-resolution CCD imaging system, precision stages with multi-axis control, and a desktop computer. The filament heater has a wide temperature tuning range that extends up to 3000 °C, which makes it possible to fuse and process various fiber types and sizes. For alignment purposes, the imaging system displays a magnified fiber image with sub-micron resolution; the camera can display views of both the fiber sides and fiber ends. Using these images, the XY and rotation stages automatically manipulate the fibers to achieve optimum positioning and ensure high-quality, low-loss splicing. The LFS4100 also has the ability to rotate fibers, making it possible to align PM fibers, eccentric core fibers, and non-circular fibers. ![]() Click to Enlarge LFS4100 Mirror Tower and Two Fibers Ready for Splicing Filament Fusion Splicing and Fire Polishing Post-fusion, a fire polishing process significantly increases splice strength through a rapid heat treatment of the splice region. In addition, the fire polishing process provides core diffusion capabilities that can be used to adiabatically expand the mode field diameter of a fiber, producing low loss splices between markedly dissimilar fibers. For more details, please see the Fusion Splicing tab. ![]() End-View Imaging for Rotational Alignment of Polarization-Maintaining and Specialty Fiber Fiber Imaging and Alignment Side view images of fibers can be acquired for all fiber diameters and used for automatic or manual XY alignment with the motion control system. In addition, end-view imaging allows for rotational alignment of polarization-maintaining and other specialty fibers. However, this end-view alignment feature is only available for fibers that can be held by the cladding or fibers that have a buffer with diameter ≤1269 microns. Larger diameter buffers will not fit in the VHB00 or the VHB05, the Fiber Holding Block Top Inserts with indents for LED end-view illumination. For more difficult alignment tasks, accurate positioning can also be achieved by maximizing the power coupled from one fiber into the other as measured by an optical power meter. Fiber Holding Block Inserts and Filaments The LFS4100 also requires a filament assembly to perform splicing operations. The filaments are omega-shaped resistive heaters capable of achieving the high temperatures required for splicing large-diameter fibers. Proper filament selection is essential for optimum splice performance. Graphite filaments are capable of heating up to the high temperatures required to splice standard and large-diameter fibers, making them ideal for most applications. By contrast, iridium filaments are preferred for splicing mid-IR fluoride fiber and other softer glasses because of their lower operating temperature. We supply filaments mounted in complete filament assemblies, which are held to the splice head of the LFS4100 by two screws. One FTAV4 Graphite Filament Assembly comes pre-installed with the LFS4100; additional graphite or iridium filaments can be purchased below. Complementary Fiber Processing Systems
![]() Fusion Splicing is the process of joining two optical fibers end-to-end using heat. The goal is to fuse the two fibers together in such a way that light passing through the fibers is not scattered or reflected by the splice while ensuring that the splice and the region surrounding it are almost as strong as the original fiber. The LFS4100 uses a resistive graphite or iridium filament shaped like an inverted omega to provide the heat necessary to fuse fibers together. Fiber Alignment The end view alignment method is used for polarization-maintaining fibers such as 3M elliptical-core fiber (PM or PZ), panda fiber, bow-tie style fiber, and for hybrid splices between any of these. For this method, images of the fiber ends are analyzed and used to automatically control both XY and rotational position. Alternatively, the active alignment method can be used for fiber that has a high core eccentricity. In this case, alignment is achieved by maximizing the power transmission between the two fibers. For more information about these advanced alignment methods, please see the Software tab.
Filament Fusion The fiber ends are allowed to heat up for a defined time before they are fused in order to remove any surface defects in the fiber ends and increase the plasticity of the glass. The user can control the power to the filament and the length of time the fibers heat up before fusion. The system's computer-controlled stepper motors push the fibers together over the pre-push distance before heating and then further move the fibers through the hot push distance to produce a splice with low loss and high strength. The total splice time, which can be adjusted by the user, is typically set between 2 and 15 seconds; common splice settings for several fiber cladding diameters are given in the table above. For special applications, the system can automatically run several splice steps in a sequence. Fire Polishing Fiber Holder Inserts Selection GuideFiber Holder Inserts, which are designed to hold various sizes of fibers within the LFS4100 splicer, must be purchased separately. The bottom inserts have V-grooves to hold the fiber, while the top inserts each feature a recessed, flat surface that clamps the fiber against the V-groove in the bottom insert. Each top and bottom insert is sold individually, as the fiber diameter clamped by the left and right holding blocks may not be the same. Two top inserts and two bottom inserts are required to operate the splicer. The table below indicates the minimum and maximum diameters that can be accommodated by different combinations of top and bottom inserts. It also indicates how far offset the fiber will be for recommended combinations of top and bottom inserts. Note that this outer diameter may be the fiber cladding, jacket, or buffer. If one side of the fiber is being discarded, it is preferable to clamp onto the cladding of this section except in special cases (such as non-circular fiber) where the coating or buffer may be preferable. Sections of fiber that are not being discarded should always be clamped on the coating or buffer in order to avoid damaging the glass. This may require different sets of fiber holder inserts to be used in the left and right holding blocks. In this case, it is important to minimize the difference in the offsets introduced by the left and right sets of inserts when attempting to produce high quality splices. ![]() Each fiber holder insert can accommodate a range of fiber sizes.
Fiber Insert Selection Chart
An Overview of the FFS3 Software Main Toolbar Each LFS4100 Filament Fusion Splicer is shipped with a desktop computer that comes with the GUI software for operating the system. This software is used to control stepper motor motion, camera image acquisition, argon flow rate, and fiber alignment mode. In addition, it is used to control splicing parameters such as splice power, splice time, pre-push distance, hot push distance, and hot push delay (see the Fusion Splicing tab for more information). An abbreviated library of splice process files for common splicing procedures is included with the software. The GUI and splice library software also enable users to create their own splice files for new processes and customize existing files as necessary. Please contact Tech Support for inquiries regarding the availability of additional splice files for your specific application. The video to the right highlights some of the main features of the software and the sections below describe some of the fiber splicing and tapering parameters that can be programmed through the software GUI. Included Splice Files
![]() Click to Enlarge Screenshot of PM Fiber Alignment Configuration Window End-View Alignment ![]() Click to Enlarge Multi-Stage Splicing Configuration The end-view alignment process is initiated by pulling the fibers back so that an end-view mirror can be inserted between two fiber end faces. An LED illuminates the fiber cladding, allowing the software to image the fiber end. Then, the image of the fiber end face is displayed and used to automatically align the cores of the two fibers. PM alignment parameters can be set for each fiber type as shown in Figure 1. This window consists of four parameters: diameter (fiber cladding), fiber type, and two PM geometry parameters for both the left and right fiber. If these parameters are not known, it is possible to directly measure them using the displayed image of the fiber end face. ![]() Click to Enlarge Active X-Y Alignment Scan Properties Multi-Stage Splicing Active X-Y Alignment
![]() Components Included
Must be Purchased Separately
Thorlabs' Vytran Filament Fusion Splicer for Standard, Large-Diameter, and Specialty Optical Fiber uses filament fusion technology to perform high-quality splicing of optical fibers with cladding diameters from 125 µm to 1.25 mm. The system consists of a filament-based heater, a stepper motor motion control system, a fiber imaging system, and a desktop computer. It is capable of splicing standard optical fiber as well as polarization-maintaining, photonic crystal, non-circular, and other specialty fibers. In addition, the system is capable of thermally expanding fiber cores and producing mode field adapters. A selection of accessories is necessary to perform fusion splicing operations with this system. The system is shipped with one graphite filament assembly installed to splice fibers with Ø125 µm to Ø600 µm claddings. Additional graphite and iridium filament assemblies for more cladidng sizes are sold separately below. Fiber Holder Inserts are available below in a variety of sizes and must be purchased separately. Nylon-tipped setscrews are used to secure the inserts in the fiber holding blocks; replacement 2-56, 1/8" long SS2SN013 setscrews are available in packs of 10. In addition, a Transfer Clamp and Graphite V-Groove (sold below) are required for the use of trasfer bottom inserts that allow multiple Vytran systems to be used together. A tank of argon gas with a purity >99.999% is also necessary and must be purchased from a third-party supplier. Please see the information below to determine the required accessories for your application. Installation and training by one of our application engineers is recommended for this system; please contact tech support for more details. ![]()
Filament Assemblies contain a graphite or iridium omega-shaped resistive heating element encased within a protective shroud. Graphite filaments are capable of achieving the high temperatures necessary for splicing large-diameter fibers, making them ideal for most applications. Iridium filaments operate at slightly lower temperatures than graphite filaments, making these ideal for working with softer glass fibers. The filaments have an approximate operation lifetime of 40 minutes, which depends on a number of factors such as argon quality, splice duration, and fiber glass quality. Thorlabs offers a selection of four graphite and three iridium filaments that are optimized for splicing fibers with cladding diameters up to 1300 µm. The filaments sold here are also compatible with the GPX3400, GPX3600, GPX3800, GPX3850, GPX4000LZ Glass Processing Systems. One FTAV4 filament comes pre-installed in the system. Additional filaments may be purchased, but before a new filament can be used in a system, it must be burned in. During the burn-in process, the filament is cycled between its operating temperature and room temperature several times. This stabilizes the thermal properties of the filament so that it produces a more consistent power output and heating performance when current is passed through it. This procedure only needs to be performed once, after which the filament will only need regular normalization. If performance begins to degrade, filament refurbishments can be ordered by contacting Tech Support. ![]()
The LFS4100 fusion splicer requires Fiber Holder Inserts to be placed in the fiber holding blocks in order to clamp the fibers during the splicing process. These top inserts sit in the lid of the fiber holding blocks and come in a variety of groove sizes. They can be used to clamp the cladding, coating, or buffer of a fiber. The top inserts and bottom inserts (sold below) can be paired in a variety of combinations to accommodate all fiber sizes compatible with the LFS4100 splicer, as described on the Fiber Holder Inserts tab above. Multiple combinations of top and bottom inserts may be required to accommodate all sizes of fiber to be spliced. There are two types of top inserts that are compatible with the LFS4100 fusion splicer. The standard top inserts (Item #'s starting with VHA) come in single-sided and double-sided versions; the specified fiber diameter (in µm) is engraved on the part. These top inserts cannot be used for end-view imaging. They are, however, compatible with the FPS300 Fiber Preparation Station, LDC Series of Fiber Cleavers, and GPX Glass Processing Systems. For end-view imaging and alignment, an insert with an indent for LED illumination (VHB00 or VHB05) is required. This mode of operation allows for alignment of the cores of polarization-maintaining, eccentric-core, and microstructured specialty fibers. These LED illumination inserts are also compatible with the GPX Series of Glass Processing Systems. While the LFS4100 can only splice fibers with cladding diameters from Ø125 µm up to Ø1.25 mm, these inserts can accommodate a wider range of outer diameters. This extended range is necessary because the fibers can be clamped on the coating or buffer instead of the cladding. ![]()
The LFS4100 fusion splicer requires Fiber Holder Inserts to be placed in the fiber holding blocks in order to clamp the fibers during the splicing process. These inserts sit in the bottom section of the fiber holding blocks and come in a variety of groove sizes. They can be used to clamp the cladding, coating, or buffer of the fiber. The top inserts (sold above) and bottom inserts can be paired in a variety of combinations to accommodate all fiber sizes compatible with the LFS4100 splicer, as described on the Fiber Holder Inserts tab above. Multiple combinations of top and bottom inserts may be required to accommodate all sizes of fiber to be spliced. Fiber Holder Bottom Inserts for larger cladding or buffer diameters (indicated with Item #'s starting with VHE) come in single-sided and double-sided versions; the specified fiber diameter (in µm) is engraved on the part. These bottom inserts can also be used in the FPS300 Fiber Preparation Station, LDC Series of Fiber Cleavers, and GPX Glass Processing Systems. Positional reference of the fibers will not be maintained when these inserts are transferred between systems. While the LFS4100 can only splice fibers with cladding diameters from Ø125 µm up to Ø1.25 mm, these inserts can accommodate a wider range of outer diameters. This extended range is necessary because the fibers can be clamped on the coating or buffer instead of the cladding. ![]()
These Fiber Transfer Components are used with the Fiber Holder Transfer Bottom Inserts sold above, which allow for a single fiber to be transferred between various Vytran systems without loss of positional reference. The VHT1 Transfer Clamp secures fibers within the transfer inserts; it is required for their use. Transfer inserts that accept cladding or buffer diameters ≤550 µm also require Graphite V-Groove tips, which help to support fibers during splicing. The table to the right gives the range of diameters compatible with each V-groove. These tips are compatible with the FPS300, LDC400, LDC400A, GPX3400, GPX3600, GPX3800, GPX3850, and GPX4000LZ Vytran systems in addition to the LFS4100 splicer. ![]() ![]() Click to Enlarge USC2 Ultrasonic Cleaner and USC2NVT Nest for Vytran Transfer Bottom Inserts ![]() Click to Enlarge The cleaning intensity and duration controls are located on the rear of the cleaner.
![]() Click for Details The USC2NVT Nest adds support for Vytran transfer bottom inserts.
Thorlabs' Vytran® USC2 Ultrasonic Fiber Cleaner is designed for volume processing of bare fiber. Adjustment knobs for cleaning intensity and cleaning duration allow the user to easily set repeatable cleaning parameters. The dunking jig offers adjustable immersion depth and is compatible with interchangeable fiber holder nests (each sold separately). A red LED indicates when the cleaning cycle is active. The 100 mL solvent tank is only suitable for use with acetone or isopropyl alcohol. Tilting the dunking jig submerges the fiber in the tank and initiates the ultrasonic cleaning process. The ultrasonic agitation ceases after the chosen cleaning duration. The height of the fiber holder above the solvent tank can be changed over a 0.5" (12.7 mm) range using the knurled adjuster on the side of the dunking jig, visible in the photo above. The knurled adjuster can also be reversed to disengage the bare fiber nest and switch it out for another fiber holder nest. Each cleaner is shipped with a bare fiber nest installed in the dunking jig. The USC2NVT Nest (sold separately) is designed for use with Vytran transfer bottom inserts. Accessories are available for the Vytran fiber nest to support a wider range of usage scenarios, including a clamp for standard bottom inserts and spacers for recessing inserts farther from the solvent tank. We also offer nests for Fujikura® and Fitel® fiber holders (each sold separately). Please see the complete product presentation for more information. | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
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