Method for cutting the wire of a fiber optic sensor

Use a specialized fiber optic cutter to make clean, precise cuts without damaging the optical fiber or its protective layers.

Tools Required

• Fiber optic cutter or cleaver: Designed to cut the outer jacket, Kevlar fibers, and the glass fiber cleanly without fraying or nicking the core .
• Kevlar scissors: For cutting the reinforcing Kevlar strands without dulling the main blade .
• Sharp utility knife or scoring tool: To score the glass fiber for a controlled break .
• Protective gloves and eye protection: To prevent injury from glass shards.

Step-by-Step Cutting Process

1. Remove the outer jacket: Use a sharp blade or wire strippers to carefully cut through the polymer jacket and pull it off, exposing the Kevlar fibers and the glass core .
2. Handle Kevlar fibers: Twist the Kevlar strands into a rope-like bundle and snip them with dedicated Kevlar scissors to prevent fraying .
3. Score the glass fiber: Lightly scratch the glass core at the desired cut point using a scoring tool or sharp knife. This creates a controlled weak point .
4. Break the fiber: Hold the fiber at the scored point and gently bend it until it snaps cleanly. Avoid crushing or applying excessive force to prevent micro-cracks .
5. Trim remaining protective layers: If necessary, use the fiber optic cutter to remove any remaining jacket or buffer layers, ensuring a perpendicular, smooth end-face .

Important Considerations

• Do not use standard wire cutters or nippers: These can crush the fiber, fray Kevlar, and reduce optical performance .
• Maintain bend radius: Avoid bending the fiber below its minimum bend radius to prevent signal loss or breakage .
• Use the correct cutter for the fiber type: Tight-buffered fibers, plastic fibers, and Kevlar-reinforced fibers may require different cutting tools .
• Clean the fiber after cutting: Remove dust or debris with a dry cloth to maintain optimal light transmission . By following these steps and using the proper tools, you can safely cut a fiber optic sensor wire while preserving its optical integrity and mechanical strength.