Simple Making of Optical Cable Bending Tool

You can create a simple optical cable bending tool using tubing and controlled heat to safely bend fiber optic cables without damaging them.

Materials Needed

• Two pieces of rigid tubing (plastic or aluminum) slightly larger than the fiber diameter
• A tray for hot water
• Boiling water and cold water for thermal shaping
• Optional: flexible ties or velcro to secure the cable after bending

Step-by-Step Guide

1. Prepare the Tubing: Cut two pieces of tubing. These will hold the fiber straight where you don't want it to bend and guide the bend at the desired location .
2. Heat the Fiber: Fill a tray with boiling water. Insert the section of fiber where the bend is needed into the tubing and submerge it in the hot water for a few seconds. This softens the fiber slightly, making it easier to bend without breaking .
3. Form the Bend: Gently push the fiber against the wall of the tray or a corner to create the desired angle. The tubing helps maintain control and prevents kinks .
4. Cool the Fiber: Remove the fiber from the hot water and immediately place it in cold water to set the bend permanently .
5. Secure the Cable: Use flexible ties or velcro to hold the fiber in place along its route, avoiding sharp angles or excessive tension .

Important Considerations

• Minimum Bend Radius: Always follow the manufacturer's recommended bend radius, typically at least 10 times the cable diameter without tension, and 20 times under tension .
• Avoid Sharp Bends: Sharp angles can cause signal loss or break the fiber. Use the tubing as a guide to ensure smooth curves .
• Testing: After bending, test the fiber to ensure signal integrity has not been compromised .

Optional Enhancements

• For repeated bends, you can create a template or jig using a curved piece of metal or plastic to standardize the bend radius.
• Using EZ-Bend compatible cables can allow tighter bends with minimal signal loss, simplifying installation in tight spaces . By following this method, you can safely bend optical fibers for small projects or installations without expensive commercial tools, while maintaining signal quality and cable integrity.