Fiber Fusion in Industrial Automation: Why DRM Invested in Splicing Technology That Strengthens Signals and Installs

Fiber Fusion in Industrial Automation: Why DRM Invested in Splicing Technology That Strengthens Signals and Installs

Fiber optic is the backbone of plant-wide communication. Whether linking remote PLC panels, SCADA systems, or running control lines across long distances, the performance of the fiber network depends on the quality of each connection.

DRM recently upgraded our in-house splicing capabilities with fiber fusion allowing tighter bends, better signal strength, and faster certification during industrial network installs. This supports both UL 508A control cabinet builds and large scale fiber backbone work inside industrial contracting projects.

The new fusion process uses the Swift KF4A all in one splicer. The Swift KF4A unit provides real time optical alignment and reports estimated and confirmed dB loss for every splice.

This article breaks down what fiber fusion is, how it improves quality, and why it makes DRM a better partner for industrial automation and electrical contracting projects.

What Is Fiber Fusion Splicing?

Fusion splicing is a method of joining two fiber optic cables end to end by using an electric arc to fuse the glass cores together. Compared to mechanical connectors, fusion splicing results in:

• Lower insertion loss (measured in decibels, or dB loss)
• Higher tensile strength and durability
• Minimal reflectance and long-term signal stability
• Tighter bend radii for compact panel routing

DRM’s new splicing machine uses optical alignment cameras and automated positioning to prep each strand, followed by real time video alignment and arc fusion. This process is now the standard for industrial terminations and replaces older mechanical end methods. Metrics prove traditional mechanical terminations have a much lower first-time pass rate than fusion.

“This is a big leap forward in how we install and certify fiber. We can now document dB loss from day one and fit tighter terminations into compact spaces,” said Barry Brian, partner at DRM, LLC.

The KF4A delivers up to 77,000 cleaves per blade and up to 38,000 splices per electrode. Field splice time averages thirty seconds per connection, improving job efficiency and reducing installation labor.

Why Fiber Fusion Matters for Industrial Clients

1. Cleaner Panel Work and Better Bends

Older fiber installs required generous loopbacks and loose radii to prevent stress fractures. Fusion splicing allows for tighter bends without compromising signal integrity.

Panels and breakout boxes now use LC connectors instead of ST or SC, allowing up to twenty four connections in the space where older connectors allowed six.

2. Reliable Signal Across Long Runs

In plants with VFDs, welders, or other EMI sources, copper networks struggle. Fiber optics resist noise, but only if your terminations are correct and remain that way throughout years of operation. Fusion splicing keeps signal strength high, even across long outdoor runs, between buildings, or even in the worst manufacturing environments throughout the network’s lifespan.

Mechanical connectors often arrived with inconsistent factory tolerances, creating unreliable links in high noise environments. Fusion splicing removes these variables.

3. Certifiable Installs from Day One

With fiber power meters and OTDR testing, DRM can certify every splice.

Fluke meters and KF4A splice reports provide timestamped dB loss records for every connection, creating a documented baseline for the client.

A Better Fit for Contracting Work

Adding fusion splicing to DRM’s contracting toolkit means fewer subs, fewer delays, and more control. External fiber installers often require additional onboarding, PPE verification, and safety training, which slows industrial work, so having this capability in-house removes that bottleneck.

On large projects like greenfield facilities or control retrofits, certified fiber installation quality reports are not just helpful, they are essential. Recent projects have included customer specifications requiring fused terminations and full dB loss documentation.

Application Examples and Industry Fit

Fiber becomes essential when CAT6 or Ethernet exceeds the 330 foot limit. Many industrial runs surpass 700, 900, or several thousand feet.

Dusty or vibrating environments require protective enclosures or transitioning to copper at the cabinet.

High noise environments such as welding bays, smelters, and areas with heavy VFD use benefit strongly from fiber due to EMI immunity.

Multi Strand Handling and Breakout Trays

Multimode fiber is typically landed in a breakout box, then fusion spliced and terminated onto an LC bulkhead. KF4A protective heat shrink sleeves include reinforcement rods that prevent bending at the splice.

Modern fiber cable designs allow tighter conduit bends, removing the need for large loop sweeps required in earlier generations.

Example Project Work

An upcoming project includes multimode terminations, Fluke testing, and full KF4A reporting. A previous job at this facility required several days using mechanical connectors. The new setup is expected to reduce this time by more than half. DRM has documented labor savings of 50% by fusion splicing instead of traditional mechanical connectors.

Fusion splicing allows us to:

• Run fiber between MCCs, server rooms, and remote control when highest network confidence is paramount.
• Extend networks across campuses or through harsh environments
• Integrate fiber within hybrid networks (copper plus fiber backbones), qualify those connections, and ensure reliability for network life.

Investing in Training, Not Just Tools

The fusion splicer is only part of the equation. DRM is investing in training across field technicians and project managers to ensure fiber work is completed in the most efficient, most perfect and most reliable method possible.

Many DRM team members have been trained on fusion splicing. That includes hands-on work with the splicer, as well as best practices for testing, documentation, and layout planning.

Barry and the leadership team are also exploring fiber certification programs that would help formalize DRM’s capabilities and build client trust even further.

The Bottom Line: Stronger Signals, Stronger Systems

Whether we are delivering a custom UL 508A control cabinet or executing a campus-wide fiber backbone, our clients should know that every connection was planned, tested, and documented to perform.

Fiber fusion helps us do that. It makes us faster. It makes us sharper. And it keeps us aligned with the way we’ve always operated: full integration from power to process.