Manual fiber routing production: how long can you keep this up?
Optical fiber flex circuits are essential to today’s technology. In aerospace, defence, automotive, information and communication, and medical devices, they enable fast, reliable data transfer. The technology is evolving fast, and demand for more complex products is growing with it. Production processes need to be flexible and efficient.
Yet production of optical fiber flex circuits is still largely manual. The advantages are lower startup costs and quick adjustments, but the process is labor-intensive, unsuited to larger volumes, and prone to quality variation.
Limitations of manual production
- Inconsistent quality
- Limited design testability
- Hard to scale
- No parallel or multi-layer production
Inconsistent quality
Manual processes are error-prone. Product quality can vary by batch or by operator.
Limited design testability
Designers must account for design rules and operator skill, such as bend radii and desired lay angles. This can complicate design feasibility. A design that turns out unmanufacturable means a costly, time-consuming revision.
Hard to scale
Manual production limits fast scaling. In a growing market, that's a problem.
No parallel or multi-layer production
Modern applications demand more than manual processes can deliver, in efficiency and in complexity.
The market is forcing change
Demand for fiber flex circuits keeps growing. The real challenge is building the flexibility production needs: fast, consistent, scalable, and at high volume. The limits of manual production are why manufacturers can't keep up with growing market demand. This underscores the importance of automation and advanced production processes.
Every manufacturing company has focus points that drive business results: maximizing production capacity, boosting efficiency, and making optimal use of labor and materials. That improves output quality, cuts costs, and shortens lead times. Three trends make it urgent to critically examine your production process now.
Market trends and customer expectations
The market for optical fiber flex circuits is changing fast. Customers want faster, more flexible, more complex solutions, and products that meet high quality standards while adapting quickly. Those who don't move with this lose competitive strength.
Competitive pressure
Competitors in the sector are switching to innovative production methods. Sticking with outdated methods risks losing market share and customer trust. Proactively evaluating and innovating is no longer optional, it's necessary.
Risk of new entrants
The barrier to entry for new players is dropping as automated solutions emerge. New entrants work faster and more efficiently, raising competitive pressure further. Manufacturers must recognize this dynamic and actively protect their position.
Download: The Future of Optical Fiber Flex Circuit Production
Demand across aerospace, medical, automotive, and telecom is rising fast, and manual production of optical fiber flex circuits can't keep pace. This whitepaper shows where manual processes cost you quality and efficiency, and how modular automation combines design, fiber routing, and coating into one machine. You'll also learn how AI further optimizes the production process.
The time for waiting is over
The conclusion is clear: manual production holds optical fiber flex circuit manufacturers back, while the market demands speed, scale, and consistent quality.
About the author
Leon van Veghel
Director Operations
About the author
Leon van Veghel
Director Operations
I am Leon van Veghel, Director Project Office & Operations at Etteplan. At Etteplan Engineering Solution Netherlands, our engineers and business consultants combine 40+ years of precision mechanics and mechatronics expertise with robotics, software, and big data technologies. Throughout my career, one thread stands out: optimizing production plants and production lines through engineering, industrial automation, and lean processes. For the past years at Etteplan, I've applied that knowledge to help customers solve their production solutions challenges. Interested in production solutions? Follow me on LinkedIn or reach out for a meaningful conversation about your situation if you want to know more.
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