Fiber Optic vs Metal Components

­The introduction of fiber optic technology has advanced the way we deliver power and communicate digitally but how does it compare to traditional cabling materials and is it sustainable? Here, Mark Baptista, internal application engineer at electrical connector specialist PEI-Genesis, explains the differences between fiber optic and metal components in cables and connectors, and how we can efficiently use them in evolving applications.

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Figure 1: Fibreco Expanded Beam MINI distributed by PEI-Genesis

The past century has witnessed major advancements in power transmission. Traditional metal cabling has long been the backbone of electrical and telecommunication infrastructure since the 1800s, becoming pivotal in developing modern telecommunication. Used across radio, television and early internet applications, it’s a staple in electronic technology that has become difficult to replace.

Yet, in the 1970’s the electronic industry was presented with an alternative. A cable where light travels through glass fibers encased in a polymer coating, capable of transmitting signals with significantly reduced attenuation. Known as fiber optic, it set a new standard for transmission speeds and became the main choice for high-speed internet, medical imaging, data centers and even military communications

Today, fiber optic technology stands as a crucial component in modern digital infrastructure, outperforming metal cabling in speed, efficiency, and reliability. However, when choosing components for your application, both fiber optics and metal can be considered based on requirements. With each type we can compare performance, cost, durability and application to determine the most efficient option.

Cost vs speed

Traditionally, metal cabling works by transmitting electric current from one place to another using the metal as a conductor. Copper and aluminum are commonly found in cables and connectors serving as excellent conductors thanks to lower levels of resistance.

Alternatively, fiber optic cables use light to transmit data. These pulses of light flow through glass fibers in the cable and provide power. Its higher bandwidth allows for faster data transmission and makes it suitable for high data rate systems.

It’s fiber optic’s speed that sets it apart from its metal counterparts. Fiber optic cables and connectors are capable of transferring data to an average of one gigabyte per second (GBPS), potentially even maxing out at several terabytes per second (TBPS) in some applications.

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Fiber’s rapid transfer speeds can depend on its optical channels – single and multi-mode. When discussing speed, traditional metal components lag, barely reaching GBPS levels. Maxing out at lower speeds makes them less compatible with high data transfer applications. However, at a cheaper cost with fiber optic two to four times more expensive in upfront costs, they are more suitable for short-term applications where high speeds are less crucial.

Considering eco-friendly power

Both metal and fiber optic components have unique environmental implications to consider, especially as industries start to prioritize sustainability. It can be a focus from the production process through to application and component disposal, making it a fundamental quality to look at when finding a suitable solution.

Traditional metal cabling requires extensive mining and refinement for raw copper and aluminum. Environmental consequences that follow can include deforestation, habitat destruction and high carbon emissions. Additionally, extraction processes can generate sulfur dioxide (SO₂), a major contributor to acid rain, and consumes vast amounts of water and energy.

Alternatively, fiber optic components use silica (SiO₂) comprised from sand. Increased abundance and easy retrieval make it far less environmentally damaging compared to copper, and while the manufacturing process involves energy-intensive melting and refining of the silica to create glass fibers, it has a lower long-term environmental impact compared to metal cable manufacturing.

Fiber is also the more energy efficient option out of the two types of components. Minimal attenuation levels in fiber optic components mean that optical signals can travel further without degradation, reducing the need for additional infrastructure to maintain transmission strength. It makes fiber optic 70 per cent more efficient than copper cabling, which experiences more interference and requires power amplification.

Though less efficient in the long term, metal components do hold some redemption when it comes to sustainability. Unlike fiber optic cables, they’re easily recyclable, as up to 90% of used copper in wire can be repurposed. Projections suggest that by 2050, nearly half of the global copper demand could be met through recycling, underscoring the importance of efficient material recovery and reuse.

Overcoming interference

Cost and the environment are not the only qualities that contribute to metal’s short-term suitability. Whilst it’s cheaper to install, maintain and recycle cables with metal components, compromised durability is the cost that comes with these installations.

Materials like copper are resistant to corrosion but can experience electromagnetic interference (EMI), which is when environmental factors interfere with the magnetic field in cabling. This makes them less suitable for applications in harsh environments, where fiber shines in comparison due to its EMI resistance.

Fiber optics’ use of light is what makes them immune to EMI. A glass or plastic core instead of metal enables data transfer through light refraction rather than current, eliminating the possibility of EMI.

EMI has an influence on the cable’s durability and how suitable they may be across long distances. Fiber optic’s EMI resistance allows data transfer across large distances, without any external interference. They may even be situated in extremely harsh environments and can withstand these conditions without compromised performance.

For instance, undersea fiber optic cables are used in global internet and telecommunication networks transmitting massive amounts of data across continents. Seawater is a conductive medium, meaning copper cables would be susceptible to a high volume of EMI and would experience power losses. This power loss would weaken the cable’s performance, which is crucial when covering such distances.  

Alternatively, metal cabling works for environments that experience less EMI, and minimal distances. For example, copper cables are used for shorter connections in data centers, like linking servers to nearby switches. Its cost-effectiveness and ease of installation make it suitable for these shorter-distance applications

EMI resistance in fiber optic cabling is most efficiently used across industries like military and aerospace where durability is valued. Military vehicles, for example, are often exposed to extreme amounts of dust, water, wind and heat.

Both metal and fiber optic cables can be durable options as both can be designed to meet IP (Ingress Protection) ratings up to IP67. For consistency, fiber optics may be the suitable choice as they are often fundamentally designed with higher IP ratings, whereas it is often something sought out for and specified in metal cabling design.

The Fibreco MAXI Expanded Beam Fiber Optic Connector supplied by PEI Genesis uses a single-mode optical channel for superior bandwidth across great distances and 16 multi-mode optical channels for high speeds across shorter distances, making it suitable for applications like data centers or military comms.

The full range of Fibreco expanded beam connectors are suited to harsh environment applications because of their durability. These connectors can withstand -40°C to +85°C when operating and have 6.7kN crush resistance —both specifications ensure performance across harsh environments.

There’s a reason why traditional cabling methods are so consistent. As an everyday short-term solution, they remain reliable and cost-effective across many industries. But as businesses seek to step up their reliability on secure and optimized power, fiber optic connectors and cables offer an exceptional option for speeder transfers even in harsher environments.

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