Fiber Optic Flex Circuit Assemblies
0 Products
What is a Fiber Optic Flex Circuit Shuffle?
A fiber optic flex circuit shuffle is a fiber routing solution that secures multiple optical fibers into a defined path on a thin, flexible substrate, reordering fiber positions from one end to the other. It enables compact, high-density routing between boards, shelves, and racks in the airflow-constrained environments of hyperscale data centers, telecommunications, and defense systems. Fibertronics manufactures fully custom Fiber Optic Flex Circuit Shuffles, designed and built to your exact requirements.
Features & Benefits
Technical Details
Routing & Configurations
Fiber can be configured in nearly any routing layout to accommodate the specific needs of a given application.
- Supports point-to-point, shuffled, or predefined patterns
- Circuit sizes from a few millimeters up to 1,760 sq in
- Typical 500 mm × 500 mm substrate fits 300+ fibers
- Fiber positioning held to ±0.01 mm for precise, repeatable routing
- Proper bend radius design supports long-term reliability, durability, and optical performance
Connector & Termination Options
Flex circuits can be terminated with a wide range of industry-standard connectors to meet the demands of high-density, space-constrained fiber optic interconnects, or provided unterminated for custom terminations.
- Supports MTP/MPO, MMC, MXC, MDC, LC, SC, and MT ferrule terminations
- Long ribbonized leads eliminate the need for splicing, for faster setup
- Unterminated option available for field or final-assembly termination
- Insertion loss under 0.1 dB, excluding connector loss.
Composition & Materials
Constructed with polyimide substrates and conformal coating adhesives, FOFCA offers robust fiber protection suitable for harsh industrial environments.
- Built from an adhesive substrate, optical fibers, protective coating, and termination connectors
- Fibers are routed to the substrate and locked into place with conformal coating
- Fiber available in singlemode, multimode, and hybrid configurations
- Standard 250 µm diameter, with specialty fiber options on request
Layer Stacking Methods
A single-layer optical plane supports anywhere from a few to several hundred or even thousands of channels. To increase channel density further, fiber channels can be multiplied through multi-layer stacking, using either physical or integrated stacking methods.
1. Physical Stacking
For most designs, keeping layer counts under five offers optimal flexibility. Multi-layer stacks beyond that are possible when needed.
2. Integrated Stacking
For highly complex routing, integrated stacking treats all layers as a single cohesive unit, enabling efficient reorganization of fiber paths.
Our Process
USA Manufacturing & Certifications
Fibertronics manufactures FOFCA assemblies at our facility in Melbourne, Florida. Our in-house design and production teams build custom fiber routing solutions to your exact specifications, with the flexibility to scale for high-volume orders.
BABA & TAA Compliant
BABA and TAA compliant options for federally funded infrastructure and government procurement.
Every Assembly Tested
Every assembly is factory tested, and each custom order includes testing specifications.
Certified Manufacturing
Fibertronics is TL9000, ISO 9001:2015, and AS9100D certified, and ITAR registered. Learn more →
Applications
From aerospace platforms to hyperscale data centers, flex circuits solve routing challenges in space-constrained, high-density fiber environments
From Concept to Production
We work closely with our customers from initial concept through full production. If you have a flex circuit project in mind, let's talk about how we can support it.
