Explosion-proof fusion splicer optimized for on-aircraft repair and maintenance of fiber optic cables.

miniature fiber optic cable fusion splicer minimod

Ruggedized explosion-proof miniature modular automatic fusion splicer

This explosion-proof miniature modular fusion splicer can go anywhere – up a ladder, hanging from overhead cable bundles, or in the tightest of cramped access panels. Originally designed for the US Navy for on-aircraft repair of fiber optic cables, the splicer can splice within one inch of any obstacle, minimizing the need for cable slack. It can splice properly whether level, vertical, sideways, or even upside down. It has been proven explosion-proof for use in hazardous environments, particularly fueled aircraft. Its shielded enclosure renders it certifiable for EMC environments, both radiated and conducted. It is packaged to withstand all environments of MIL-PRF-28800. And with the low-profile sliding fusion cover it needs only minimal clearance from overhead obstructions.

ATEX Certification

atex certificate

ATEX certificate (click here to enlarge

The Explosion-Proof Fusion Splicer (EPFS X) is a field-portable ruggedized fusion splicing system which has been qualified to IEC 60079-0 and IEC 60079-2 for use in potentially hazardous locations identified by ATEX Zone 1 or NFPA 70 Div 1 Class 1. The IECEx safety classification is II 2 G Ex pxb IIC T4 Gb. It is designed to enable high yield low-loss fusion splicing of fiber optic cables for repair or installation in hazardous locations under a variety of adverse conditions.

EPFS X Specifications

Parameter Value
Fusion Head
Size 2 x 4 x 5.25 inches (5.1 x 10.1 x 13.3 cm), or 42 in³ (685 cc) volume
Weight 30 ounces (0.85 kg)
Alignment Type Fully automatic 3-axis fiber alignment
Alignment technology PAS (Profile Alignment System)
Fiber types all standard single mode and multi- mode, including matched clad, dispersion shifted, NZ-DS, DCF, Er-doped, and large- core
Core diameters 3 microns to 200 microns
Cladding diameters 100 to 140 microns in PAS automatic mode, up to 250 um in manual mode
Buffer diameters 250 to 900 um depending on fiber holders
Typical splice loss 0.02 dB or on SMF, 0.01 dB on MMF
Arc high frequency AC, tungsten electrodes
Electrode life 3000+ arcs typical on SMF
Imaging Sub-pixel image processing in both x and y axes simultaneously
Alignment range 125 um in x and y axes, 2.5 um in z-axis
Ambient operating conditions -10 to +55 C (14 to 131 F), 0 - 95% RH
Storage temperatures -55 to +71 C
Altitude up to 5000 meters (16,400 feet)
Size 4.0 x 4.75 x 7.75 inches (10.2 x 14 x 19 cm)
Weight 4 pounds (1.8 kg)
Controller Built-in high speed microprocessor
Monitor size 3.5 inch diagonal
Operator input 6 soft-touch keys
Data display menus for splicing control, profiles selection, data files, downloads, machine settings, and control
Loss estimates splicer estimates extrinsic splice losses by PAS
Splice data memory 10,000 files capacity; stores date, time, splice number, profile used, loss estimate, and splice image
Date/time continuous, non-volatile, user-re- settable
Power supply/charger AC input, auto-ranging, 100 – 240 VAC, 50/60 Hz
Battery Operation 12 volt operation - from battery belt, vest, or vehicle using cigarette lighter plug; 86 W peak.

Product specifications subject to change without notice.

EPFS X Features

miniature fiber optic cable fusion splicer minimod

EPFS X fusion splicer head

  • By far the smallest fusion head on the market
  • MIL-spec: the most rugged fusion splicer available
  • Separable control unit can be located anywhere for convenience
  • Separable fiber holders
  • Real time active 3-axis fiber alignment
  • Automatic fiber alignment in both axes simultaneously
  • Automatic fiber screening for imperfect cleaves
  • Fiber end angle measurement and gross defect detection
  • Splice data memory, up to 10,000 splices
  • 100 splicing program capacity

EPFS X Benefits

  • Modules so small they can be carried anywhere - up a ladder, in a vest or tool belt
  • Removable fiber holders minimize the need for operator skill and attention in fiber preparation
  • Splice anywhere the user's hand can work
  • Operates in any orientation - horizontal, vertical, sideways, even upside down
  • Compact head can splice within one inch of wall or conduit, minimizing the need for slack fiber
  • Shielded enclosure both excludes the ambient environment and insures EMC compliance
  • Insertion losses on SMF typically 0.02 dB

Standard Accessories

  • Spare electrodes
  • Left and right fiber holders
  • Power supply
  • 4.5 A-hr battery and battery charger
  • Umbilical Cable
  • Fiber stripper
  • Fiber cleaning and protection supplies
  • Maintenace tool kit
  • AC power cord
  • User manual
  • Padded carrying case


  • Velcro-mountable work tray
  • Thermal stripper for automatic fiber stripping
  • Fiber holders for most fiber coating and cable sizes
  • Aurora's revolutionary new automatic precision fiber cleaver
  • Clip-on heat oven for heat-shrink splice protection sleeves
  • Portable 7.5 A-hr 12 VDC battery belt or vest