Fiber Optics Penetrate Harsh Environments

Fiber Optics Fiber Optics Penetrate Harsh Environments

2025-11-13 From Harry Jacob* | Translated by AI 4 min Reading Time

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Dirt, moisture, and vibrations pose challenges for fiber optic applications. Equipped with robust connectors, the fast and lightweight connection technology can now also leverage its advantages in harsh environments.

Fiber optic technology  for harsh  environments:  Thanks to sophisticated methods for beam expansion and focusing, fiber optics can also be used in harsh environmental conditions.(Image: Rosenberger) — Fiber optic technology  for harsh  environments:  Thanks to sophisticated methods for beam expansion and focusing, fiber optics can also be used in harsh environmental conditions.
(Image: Rosenberger)

Fast data transmission is becoming increasingly important in many areas today. Reasons include the increased use of image and video data, the growing deployment of AI applications and cloud services, as well as the ongoing digitalization.

A key metric is provided by the annual statistics of the German internet hub DE-CIX with its globally distributed data exchange points. In 2024, it recorded a global data traffic of 68 exabytes, an increase of 15 percent compared to 2023 (59 exabytes). The daily record saw a rise from 22.36 to 24.92 TBit/s, an increase of 11.4 percent.

This growth is only possible through the increasing use of fiber optic connections, which provide high bandwidths with low latency. Advances in transmission standards and connectors also enable more efficient use of individual fibers as well as easier bundling in limited space.

In data centers, fiber optics are already standard, and the connection of households and business locations is increasingly being switched from copper to fiber optics (FO). However, there are still areas where FO has not yet become established—as it is difficult to handle.

The transition from one fiber to the next is sensitive to contamination and moisture. Similarly, mechanical stresses and vibrations can impair or even interrupt data transmission. High temperatures and frequent mating cycles were also arguments against the use of optical fibers. In harsh environments, such as in manufacturing industries, users therefore often rely on copper cabling.

Beam Expansion for Less Sensitive Fiber Optics

A first step towards more robust fiber optic connectors was achieved with the principle of beam expansion, which was further optimized with the EBO ferrule concept (Expanded Beam Optical). This was followed by robust connector systems from the EBM series (Expanded Beam Multifiber). The S-RMC and MIL13 connectors, developed in-house by Rosenberger Hochfrequenztechnik according to common industry standards, combine the robust EBO signal transmission with insensitive and stable housings.

The principle of beam expansion

Traditionally, signal transmission from one optical fiber to the next is achieved through physical contact (PC). The two fibers must be precisely aligned, i.e., centered and on a common axis. Additionally, the contact surface must be extremely clean, as dust and dirt would severely impair signal transmission. There is also the risk of fiber ends being scratched, which would affect the optical properties. Such connections are also sensitive to mechanical stresses and vibrations.

Using expanded beam technology, the connection becomes less sensitive to contamination. Shaped spherical lenses at the end of the optical fibers expand the focused light beam to a larger area and refocus it on the other side. Instead of a direct fiber-to-fiber contact, the light is transmitted through a free-space zone between the lenses—although still parallel to the alignment of the fiber, meaning there remains a risk of signal attenuation if the centering or alignment angle is not precisely maintained.

The EBO (Expanded Beam Optical) connector concept also expands and refocuses the light beam when transitioning from one fiber to another. However, it does so not along the fiber axis but using lenses with an elliptical cut that act like a collimator, thereby increasing the tolerance range. This ensures that the light beams are always correctly aligned, even if the fiber is not precisely positioned due to vibrations or mechanical stresses. At the same time, interference from particles is minimized, as pollen or intruding dirt only block a small part of the enlarged light area. The light beam is no longer fully or largely obstructed but only slightly attenuated. This preserves the full ability for data transmission.

Inside, there are ferrules that can hold between 2 and 16 single-mode or multi-mode fibers as needed. The robust connectors are designed for harsh conditions and up to 5,000 mating cycles. They ensure a reliable, low-loss connection with standardized formats (SC footprint) and allow for quick, intuitive installation without extensive training. The connectors are easy to clean without the need for special tools. The connector design is optimized for high performance with minimal space and weight requirements.

Challenges in the Manufacturing Industry

Image 1:  The EBO connector concept expands the light beam during the transition from one fiber to another and then focuses it again.(Image: Rosenberger) — Image 1:  The EBO connector concept expands the light beam during the transition from one fiber to another and then focuses it again.
(Image: Rosenberger)

In production, network components face various challenges: extreme or highly fluctuating temperatures, dust and dirt, liquids and chemicals, as well as vibrations and mechanical stresses. At the same time, there are high demands for reliability, as unplanned failures or plant downtime result in significant costs. The plug-and-play design of the EBM connectors in compact form factors (S-RMC, MIL13) simplifies installation and minimizes maintenance, reducing system downtime. The space-saving design, accommodating 2 to 16 single-mode or multi-mode fibers in a single connector, addresses the confined conditions in control cabinets and on control panels.

Another challenge is the increasing bandwidth requirements in factories. On one hand, growing digitalization means more sensors and actuators are being connected, while the use of image and video recordings in production processes is also rising sharply. Consequently, increasingly larger amounts of data, sometimes in real-time, must be transmitted and processed. This goes hand in hand with increasing automation, up to (partially) autonomous systems, which in turn require additional efforts to maintain safety and security. The resulting data volumes are best handled with fiber optics, which also offer an advantage in minimizing latency. (kr)

Harry Jacob is a freelance journalist in Augsburg, Germany.

Fiber Optics Fiber Optics Penetrate Harsh Environments

Beam Expansion for Less Sensitive Fiber Optics

The principle of beam expansion

Challenges in the Manufacturing Industry

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