Comparison between Mechanical Splicing and Fusion Splicing

Mechanical Splicing:

Mechanical splices are simply alignment devices, designed to hold the two fiber ends in a precisely aligned position thus enabling light to pass from one fiber into the other. (Typical loss: 0.3 dB)

Fusion Splicing:

In fusion splicing a machine is used to precisely align the two fiber ends then the glass ends are "fused" or "welded" together using some type of heat or electric arc. This produces a continuous connection between the fibers enabling very low loss light transmission. (Typical loss: 0.1 dB)

Core mechanical splice structure

Which method is better?

The typical reason for choosing one method over the other is economics. Mechanical splicing has a low initial investment ($1,000 - $2,000) but costs more per splice ($12-$40 each). While the cost per splice for fusion splicing is lower ($0.50 - $1.50 each), the initial investment is much higher ($15,000 - $50,000 depending on the accuracy and features of the fusion splicing machine being purchased). The more precise you need the alignment (better alignment results in lower loss) the more you pay for the machine.

As for the performance of each splicing method, the decision is often based on what industry you are working in. Fusion splicing produces lower loss and less back reflection than mechanical splicing, because the resulting fusion splice points are almost seamless. Fusion splices are used primarily with single mode fiber, where Mechanical splices work with both single and multi-mode fiber.

Many Telecommunications and CATV companies invest in fusion splicing for their long haul single mode networks, but will still use mechanical splicing for shorter, local cable runs. Since analog video signals require minimal reflection for optimal performance, fusion splicing is preferred for this application as well. The LAN industry has the choice of either method, as signal loss and reflection are minor concerns for most LAN applications.

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