Custom extruded filler rods and buffer tubes for reliable fiber-optic cable production. Fiber-optic cable makes it possible for people to connect — and extruded plastic components make producing that vital technology possible.
Low-loss optical fiber has been one of the most transformative innovations of the past half-century, enabling many of the technologies people rely on today — including voice and data communications.
Before 2020, the ability to connect virtually was considered a convenience. Today it's essential — for business, telemedicine, education, and human connection.
Extruded plastic buffer jackets protect the fibers inside, much like the exterior of any common household cord — the difference is what's inside. Manufacturers configure cables differently depending on the application:
Stranded buffer tubes typically contain 12 or more fibers (sometimes ribbons). But some applications call for lower fiber counts while still requiring the same cable dimensions as a standard count. That's where filler rods come in.
Imagine lying on a pool raft filled only halfway with air — it would fold and crumple underneath you. That's what would happen to a fiber-optic cable without filler rods. They provide stability to cables that have lower fiber counts but require the same dimensions as those with higher counts.
Filler rods also streamline production, letting manufacturers continuously produce buffer tubes in a single dimension that accommodates any fiber count.
Two main polymers are used for filler rods: solid or foamed high-density polyethylene (HDPE), or polypropylene (PP — either a homopolymer or a polypropylene-polyethylene copolymer). HDPE is cost-effective for these applications, while PP costs more but offers better mechanical and physical properties that keep it from sticking to the buffer jacket.
Maintaining tolerance is critical when producing fiber-optic filler rods, so it's important to select a contract manufacturing partner with a robust quality program and sector experience. ISO 9001:2015 certification is a great start — followed, if possible, by a facility visit to observe their quality processes in action.
You deserve great results — and a team that's dedicated to helping you keep our world connected.
If you're looking for a partner for extrusions in your telecommunications application, Custom Profiles can help. Call our technical team at229-423-2929or request a consultation for your fiber-optic cable components.