Ultra-Low-Loss Fiber Optics
Mapping and ranking next-generation hollow-core fiber technologies that can integrate into existing networks to double backbone capacity for 5G backhaul and AI data-center interconnects.
Client
Tier-1 Telecom Operator
Objective
Identify & Prioritise Hollow-Core/PBG Fiber
Timeline
10-Week Sprint
Key Focus
Legacy Network Integration
The Challenge: Breaking the Shannon Limit
As data traffic soars, conventional silica fibers are approaching their capacity limits. Next-generation hollow-core fibers promise to double capacity, but their deployment is blocked by three major engineering hurdles.
Mass-Manufacturing Precision
Sub-micron core structures must remain perfectly concentric over tens of kilometers of fiber, a process where draw-tower yields are still below 60%.
Connector & Splice Compatibility
New hollow-core fibers misalign with legacy connectors, risking significant signal loss and creating integration challenges.
Bending & Micro-Slip Losses
Real-world ducts impose tight bends that cause excess signal loss in air-core fibers without the use of novel protective jacketing.
Key Outcomes: Five Lead Pathways for Network Integration
Our 6-phase sprint, including cost and yield modeling, delivered five pilot-ready solutions that address the core challenges of performance, cost, and compatibility.
Nested Anti-Resonant Hollow-Core (NANF)
A novel fiber design with a UV-cured jacket that achieves 0.17 dB/km attenuation and extremely low bend loss.
Hypocycloid PBG Fibre Splicing
A filament-fusion technique that enables splicing to legacy fiber with an average loss of just 0.04 dB.
Expanded-Beam LC Connector
A connector insert that allows for field installation in under 2 minutes with minimal signal loss.
Auto-Tension Draw Tower
A manufacturing process with machine-vision control that boosts good-length yield to 72%.
3D-Printed Hybrid Sleeve
A low-cost ($3/connector) solution for compensating core misalignment.
Strategic Impact
The telecom operator approved a 15-km pilot in its Frankfurt metro ring using the recommended NANF fibre and expanded-beam connectors. Success will position the network to double its backbone capacity without trenching new ducts, delivering a competitive edge for cloud, 5G backhaul, and latency-sensitive AI workloads.