Optical Fibre Fabrication

By
Dr Sunil Joshi
 Optical Fiber
• The optic core is the light carrying element at the
the optical
center of fiber. outer jacket
– Commonly made from a strength material
combination of buffer material
optic cladding
silica and germanium.
optic core
• Surrounding the core is the optic cladding.
– Made of pure silica.
–The difference in materials
between core and cladding is
important ...
• Buffer material helps shield the core and cladding
from damage.
• Strength material helps prevent stretch problems when
the fiber cable is being pulled.
• Outer jacket protects against abrasion, solvents, and
other contaminants Optical Comm- Dr Sunil Joshi
OPTICAL FIBER

Optical Comm- Dr Sunil Joshi

 Fibre Fabrication: Selection of Material
While selecting materials for manufacturing Optical Fibre,
a no. of requirements must be satisfied e.g.
Material should be capable of providing long, thin, flexible
fibres.
The material should be transparent at a particular
wavelength, for efficient light guidance.
Physically compatible materials having slightly different
refractive indices for core and cladding must be available.
The materials satisfying above requirements are: Glass
and Plastic. Majority of fibres are made up of glass
consisting of Silica (SiO2 ), or silicates.

Optical Comm- Dr Sunil Joshi

From materials view points we have
following fibres:

Glass Fibres
Halide Fibres
Active Glass Fibres
Plastic Clad Glass Fibres
Plastic fibres

Optical Comm- Dr Sunil Joshi

Glass Fibres
Glass is made by fusing mixtures of metal oxides,
sulphides, or selenides having randomly connected
molecular network rather than a well defined ordered
structure as found in crystalline materials.
That is why glasses do not have a well defined melting
points.
When heated, remains in solid state up to several
hundreds degree Celsius of temp.
As the temp. rises to very high values, it becomes a
viscous liquid.

Optical Comm- Dr Sunil Joshi

The largest category of optically transparent glasses
from which optical fibres are fabricated, consists of the
oxide glasses. The common fibre compositions are:

GeO2 –SiO2 : Core; S iO2 : Cladding

P2O5 –SiO2 : Core; S iO2 : Cladding

SiO2 : Core; B2O3 –SiO2 : Cladding

GeO2 –B2O3 -SiO2 : Core; B2O3 –SiO2 : Cladding

The principal raw material for Silica (SiO2) is sand.

Glass composed of pure Silica is referred to as
Silica glass or fused glass or vitreous Silica.

Optical Comm- Dr Sunil Joshi

Halide Glass Fibres

Glasses in which anions are from elements in

group VIII of P.T. namely fluorine, chlorine,
bromine, & iodine.
The materials that researchers have
concentrated on is a heavy metal fluoride glass,
which uses ZrF4 as the major component &
glass network former.
Although these glasses offer extremely low
losses, fabricating long lengths fibres is difficult.

Optical Comm- Dr Sunil Joshi

Plastic Clad Fibres

Made of Silica Core and Clad of Polymers

(Plastic) material.
A common cladding material is silicon resin
(n=1.405 at 850 nm).
Other material is Teflon (n=1.38, gives large
N.A.)
Such fibres are used for short distance
applications up to several hundred meters.

Optical Comm- Dr Sunil Joshi

Fabrication Methods

Direct Melt method

Vapour Phase Oxidation Process

Direct Melt method

Direct melt method follows traditional glass
making procedures in which the optical fibres are
made directly from the molten state of the
purified components of silicate glasses.
Optical Comm- Dr Sunil Joshi
Vapour Phase Oxidation Process

In vapour phase oxidation process, highly pure vapours

of metal halides (e.g. SiCl4 & GeCl4) react with O2 to form
a white powder of SiO2 particles.
These particles are then collected on the surface of a
bulk glass, and then sintered (transformed to a
homogeneous glass mass by heating without melting) to
form a clear glass rod or tube (depending on process).
This rod or tube is called ‘PREFORM’.
Preform is typically 10-25 mm in diameter and 60-120
mm long.
Fibres are then drawn using the fibre drawing
equipment.

Optical Comm- Dr Sunil Joshi

 How are Communication
Optical Fibers made?

• Three Steps are Involved

- Making a Preform Glass Cylinder

- Drawing the Fibre’s from the preform
- Testing the Fibre

Optical Comm- Dr Sunil Joshi

 PREFORM FABRICATION PROCESS

• Purification of Raw Materials.

• Transport of Reactants to Heat Source.
• Chemical Reactions and Particle
formation.
• Particle collection.
• Drying and Sintering.
• Preform Design.

Optical Comm- Dr Sunil Joshi

 TYPICAL MATERIAL COMBINATIONS FOR
OPTICAL FIBERS

CORE DEPOSITED CLAD

• GeO2- B203-SiO2 • B2O3-P2O5-SiO2
E
MULTIMOD

• B2O3-P2O5-SiO2
• GeO2-P2O5-SiO2 • F-P2O5-SiO2
• GeO2-SiO2 • SiO2

• F-P2O5-SiO2
• SiO2
SINGLE MODE

• GeO2-SiO2
• P2O5-SiO2
• F-SiO2
• SiO2
• F-P2O5-SiO2
Optical Comm- Dr Sunil Joshi • F-SiO2
 Fabrication Techniques

 MODIFIED CHEMICAL VAPOUR DEPOSITION (MCVD)

 OUTSIDE VAPOUR DEPOSITION (OVD)

 VAPOUR AXIAL DEPOSITION (VAD)

Optical Comm- Dr Sunil Joshi

 MODIFIED CHEMICAL VAPOUR DEPOSITION
(MCVD) PROCESS

It involves depositing high purity material on the

inner surface of a tube, collapsing this composite
to form a preform rod comprising the core/clad
structure and drawing this preform into controlled
diameter light guide fiber

 First described by MacChesney et al. in

1974 at AT &T Bell Labs
 Most simple, versatile, flexible &
widely used
 Used for drawing both S.M fibers and M.M
fibers.
Optical Comm- Dr Sunil Joshi
MODIFIED CHEMICAL VAPOUR DEPOSITION
(MCVD) PROCESS (contd.)

 Germanium dioxide as dopant to increase R.I

 Fluorine to decrease R.I
 B2O3 and P2O5 to decrease the processing temp.

 Typical core GeO2- P2O5-SiO2

 Cladding Barrier P2O5- B2O3-SiO2/P2O5-F-SiO2
 Substrate Cladding SiO2
 Diffusion of Ge to surface during Collapse gives
Centre Dip in RIP which is removed by flowing small
quantity of GeCl4 during collapse

Optical Comm- Dr Sunil Joshi

 MODIFIED CHEMICAL VAPOUR DEPOSITION
(MCVD) PROCESS - SCHEMATIC
The deposition phase of the process is based on the
high temperature oxidation of SiCl4 and other dopant halides
to form high silica glass compositions

Optical Comm- Dr Sunil Joshi

Steps for Making Fiber Preform using
MCVD Method
• Prepare a silica tube (glass extrusion).
• Heat the tube
• Inject SiCl4 and O2 into the tube
• At the heated portion, the SiCl4 is
oxidized
SiCl 4  O2 hta
e
SiO
2  2
2Cl pure SiO is deposited on the
• UItra 2
inner walls of the tube
• Draw the tube through the furnace,
continuously coating the inner walls.
– SiO2 particles deposit and sinter
along the tube
Optical Comm- Dr Sunil Joshi
CHEMICAL REACTIONS AND PARTICLE
FORMATION

• SiCl4 + O2 SiO2+2Cl2

• GeCl4 + O2 GeO2+2Cl2

• 2H2O +2Cl2 4HCl + O2

• GeO2(s) GeO (g) + ½

O2(g)

Optical Comm- Dr Sunil Joshi

MODIFIED CHEMICAL VAPOUR DEPOSITION
(MCVD) PROCESS

Optical Comm- Dr Sunil Joshi

PREFORM MAKING BY MCVD PROCESS
Optical Comm- Dr Sunil Joshi
Particle Growth Trajectories in MCVD
Optical Comm- Dr Sunil Joshi
TRANSPARENT PREFORM CONTAINING BUBBLES

Optical Comm- Dr Sunil Joshi

MCVD PRODUCTION LATHE
UNIT

PREFORM PRODUCTION AREA

AT AT&T TECH. USA

Optical Comm- Dr Sunil Joshi

MULTIMODE GRADED-INDEX FIBER DESIGNS

Optical Comm- Dr Sunil Joshi

 SIMPLE

TRIANGLE

DESIGN
GRADED FLEXIBILITY

DEPRESSED
CLAD

DOUBLE

CLAD(W) WIDEBAND

QUADRUPLE CLAD

SINGLE MODE
FIBER
DESIGNSOptical Comm- Dr Sunil Joshi
 OUTSIDE VAPOUR DEPOSITION
(OVD) PROCESS
 Invented by Keck and Schultz at CORNING
GLASS WORK, USA in 1973

 Both step index and graded index fiber

designs can be achieved.

 Complexity and custom designed equipment

have caused restricted use of the process.

Optical Comm- Dr Sunil Joshi

 a) Soot Deposition
b) Sintering
c) Fiber Drawing

OUTSIDE VAPOUR DEPOSITION (OVD) PROCESS

Optical Comm- Dr Sunil Joshi
 VAPOUR PHASE AXIAL DEPOSITION
(VAD) PROCESS

 First described by IZAWA et. al at NTT, Japan in

1977
 Continous fabrication process of fiber preform in axial
direction
and preferred for mass production
 Deposition and consolidation steps are arranged in sequence.
 Long and large diameter preform can be produced,
thereby, reducing significant cost in fiber production
 Raw materials such as SiCl4, GeCl4, PoCl3 and BBr3 are fed
from the bottom into oxyhydro flame
 Porous preform produced by depositing glass particles
by flame hydrolysis reaction is consolidated by zone
melting in carbon ring heater.
Optical Comm- Dr Sunil Joshi
VAPOUR PHASE AXIAL
DEPOSITION
(VAD) PROCESS

Optical Comm- Dr Sunil Joshi

POROUS PREFOM PARTIALLY CONSOLIDATED

Optical Comm- Dr Sunil Joshi

VAPOUR PHASE AXIAL DEPOSITION (VAD) PROCESS

Optical Comm- Dr Sunil Joshi

OPTICAL FIBER DRAWING MECHANISM

Optical Comm- Dr Sunil Joshi

 Fibre Drawing

Optical Comm- Dr Sunil Joshi

 Optical Fiber Drawing & Coating Unit
• Fibers are drawn at 30
to 60 ft/s
2000 °C
• Multiple polymer coatings may
be applied
– Thermoplastic (buffer)
– PVC of fluoride co-polymer
• Spools of up to several km
are wound.

Optical Comm- Dr Sunil Joshi

 OPTICAL FIBER
DRAWING
AREA

Optical Comm- Dr Sunil Joshi

 FACTORS AFFECTING THE MECHNICAL STRENGTH
OF FIBERS PULLED IN GRAPHITE FURNACE
PROPERTY MAJOR FACTOR MINOR FACTOR NO OBSERVABLE
INFLUENCE
Preform MATERIAL GRADE: Synthetic Residual
Quality silica has higher strength strain/small surface
than natural quartz. marks:
Preform cleanliness: Eliminate by flame
Ideal clean : HF wash and polishing and
flame polish annealing

Furnace Contamination by graphite Abrasion of Furnace preheating:

Environment dust and impurities: preform at top seal: Preheat for several
Reduced by: Eliminate top seal hours before fiber
1. High grade graphite. pulling
2. Prolonged burn-in period.
3. Optimize gas-flow pattern
Fiber-forming Temperature/pulling tension: Temperature Fiber cooling rate:
Process Control by optimizing profile: Use forced gas
furnace temperature and Alter hot zone cooler to accelerate
pulling speed profile by heating cooling rate
element
arrangement

Optical Comm- Dr Sunil Joshi

 Contd…
PROPERTY MAJOR FACTOR MINOR FACTOR NO OBSERVABLE
INFLUENCE
Primary coating Decentered coating: Irregular coating: Fiber- polymer
Crucible alignment to Vibration. Fiber attenuation:
< 1mm temperature too high Optical attenuation of
Coating thickness: at crucible. fiber polymer coat
Crucible design: unrelated to strength
Minimum thickness for
soft silicone coat 1.Tapered tip gives Pulling speed:
>30mm lower eccentricity. No effect on coating
Polymer cleanliness : 2. Flexible tip gives quality
Filter to eliminate dust a
and impurities thicker coating

Fiber handling Surface damage: Thermal expansion

Use Teflon-coated differences:
pulling drum/expanded cool fiber before
polystyrene storage winding on drum
drums

Optical Comm- Dr Sunil Joshi

Glass Fiber Drawing by Double Crucible Method

This method has

become important in the
production of
inexpensive fiber by a
continuous process.

The starting materials

may be fed in either
powdered form or by
means of high purity
preformed rods.

Optical Comm- Dr Sunil Joshi

 Double Crucible Method
(Contd.)
Double crucible mounted inside a vertical,
silica lined muffle furnace capable of raising
the melt to between 1000-1200oC.
An inert gas atmosphere is maintained inside
the furnace.
Control of the core and cladding diameters
are maintained by the fiber pulling speed and
the head of molten glass in each crucible.
With a suitable choice of materials and
control of the melt temperature at the nozzle,
index grading can be obtained by ionic
diffusion.

Optical Comm- Dr Sunil Joshi

DIMENSIONS OF TYPICAL DOUBLE CRUCIBLE

R1: 0.5-1.5mm
R2: 2-3mm
A1: 5-15mm
A2: 40-50mm
h1:30-80mm
h2: 30-80mm
h3: 40-100mm
I1: 8-24mm
I2: 15-30mm
I3: 10-30mm

Optical Comm- Dr Sunil Joshi

Optical Comm- Dr Sunil Joshi
 GLASS FIBER DRAWING WITH
ROD - IN - TUBE METHOD

Core Heater

Cladding

Optical Comm- Dr Sunil Joshi

Fiber Drawing Machine Developed at CSIR
Optical Comm- Dr Sunil Joshi
 WHY CABLING?

• EASE OF HANDLING THE FRIGILE FIBER

• PROTECTION FROM DAMAGING

FORCES

• ENVIRONMENTAL PROTECTION

Optical Comm- Dr Sunil Joshi

CABLED FIBER

Optical Comm- Dr Sunil Joshi

Cross - Sectional View of Six Fiber
Telecommunication Cable

Optical Comm- Dr Sunil Joshi

Fiber Cable View

Optical Comm- Dr Sunil Joshi

Various Types of Fiber Cables
Optical Comm- Dr Sunil Joshi
Fiber Cable Manufacturing Process
Optical Comm- Dr Sunil Joshi
Fiber Cabling Machine
Optical Comm- Dr Sunil Joshi
Fiber Cabling Machine
Optical Comm- Dr Sunil Joshi
Cabled Fiber Rolls/Spools

Optical Comm- Dr Sunil Joshi

 REFERENCES
1. Fiber Optics : Principal and Applications
NS Kapany, Academic Press, New York, London
2. Fiber Optics : Theory & Practice
W.B. Allen, Plenum Press, London, New
3. Fiber Optics : Edward A.
Lacy Prentice Hall, New
Jersy
4. Optical Fiber Communication Vol 1
Fiber Fabrication Edited Tingye Li
Academic Press Inc., New York
5. Hand book of Fiber Optics,
Y Chai A, Academic Press
6. Understanding Fiber Optics
Jeff Hecht Upper Saddle River, New Jersy
Colombus, Ohio
 Thank you

Any question!

Optical Comm- Dr Sunil Joshi