Optical Flex Circuit
Custom Optical Flex Circuit for High-Density Fiber Routing
Turn a complex fiber map into an organized, low-profile assembly for CPO, OCS/OXC, optical backplanes and compact optical equipment.
Category Products
Optical Flex Circuit Product Range
Optical Flex Circuit
Fiber Shuffle Flex Circuit
01 · Product Overview
What Is an Optical Flex Circuit?
An optical flex circuit—also called a fiber flex circuit or fiber shuffle circuit—organizes multiple optical fibers on a flexible substrate according to a defined routing map.
Instead of managing individual fibers as a loose bundle, the paths, exits and channel relationships are planned as one documented assembly. This format is useful for card-to-card, backplane, cross-connect and other internal optical interconnect applications.
What is fiber shuffle? Fiber shuffle is a predefined remapping of optical channels so each input port is routed to a specific output port in a fixed pattern. It is commonly used inside co-packaged optics (CPO), optical circuit switches (OCS), optical cross-connects (OXC) and compact optical backplanes where space is tight and channel order must be controlled.
Predefined mapping
Plan every channel relationship before assembly and preserve it in the approved route table.
Compact format
Organize multiple optical paths as one low-profile assembly for space-constrained equipment.
Controlled exits
Define lead-out side, position, pitch, length and tolerance around the mechanical envelope.
Cleaner integration
Reduce loose-fiber routing complexity through documented geometry, labels and interface locations.
Repeatable build
Align design, inspection and installation around one controlled drawing and fiber map.
Product Gallery
Optical Flex Circuit & Fiber Shuffle Configurations
02 · Routing Logic
How Does Fiber Shuffle Mapping Work?
Select a topology to see how a documented route can organize channel relationships within one flexible assembly.
Engineering view
Point-to-point routing
Each input follows a direct, documented route to its assigned output.
Routing diagrams illustrate logic only. The approved fiber map and mechanical drawing govern production.Start with the fiber map
Why Is the Fiber Map the Product Definition?
Each project begins with the required input-to-output relationship, the available space and the location of every fiber exit.
- Fiber mappingCustomer-defined
- TerminationProject-defined
- Form factorCompact & flexible
- Release basisApproved drawing
03 · Engineering Inputs
How to Specify a Custom Optical Flex Circuit
Use these fields to prepare a meaningful feasibility review. Final materials, dimensions, optical performance and terminations are confirmed in the approved project drawing.
| Design field | Define the requirement | Send with the RFQ |
|---|---|---|
| Routing topology | Point-to-point, shuffle, fan-out or another logical map | Port-to-port mapping table |
| Fiber requirement | Singlemode, multimode or specialty fiber | Fiber specification and wavelength |
| Mechanical envelope | Outline, keep-out areas and mounting constraints | 2D or 3D equipment drawing |
| Fiber exits | Side, position, pitch, lead length and tolerance | Every exit marked in the drawing |
| Termination | Ferrule, connector, bare fiber or splice-ready lead | Interface list and orientation |
| Polarity & IDs | Channel relationship, labels and color rules | Polarity or pin-out schedule |
| Optical criteria | IL, RL, continuity, length match or skew | Limits, wavelengths and test method |
| Environment | Temperature, humidity, vibration and compliance | Required standards and conditions |
Choose the Right Format
Optical Flex Circuit vs. Fiber Harness, MPO/MTP Harness and Shuffle Box
Choose an optical flex circuit when the equipment envelope is constrained and the fiber map is complex and fixed. Use a fiber harness or ribbon assembly for simpler, more flexible runs. Use a shuffle box when the cross-connect must be serviceable at rack level.
| Solution | Best fit | Routing | Physical form |
|---|---|---|---|
| Optical Flex Circuit | Equipment interior, backplane and board-level routing | Predefined complex map | Flat, flexible assembly |
| Fiber Harness | General equipment and chassis connections | Individual leads or bundled branches | Round cable or loose bundle |
| MPO/MTP Harness | Connectorized equipment or patch-panel fan-out | Connector and polarity-defined breakout | Round or ribbon cable assembly |
| Shuffle Box | Rack- or equipment-level fixed cross-connect | Mapped inside an enclosure | Module or chassis |
| Ribbon Assembly | Regular parallel channel runs | Usually limited crossing | Flat parallel ribbon |
04 · Intended Applications
Where Optical Flex Circuits Fit in CPO, OCS/OXC and Optical Backplanes
Application fit is evaluated against the specific equipment design; these are engineering contexts, not published customer deployments.
CPO & Near-Package Optics
Evaluate internal routing between optical engines, board-level interfaces and front-panel terminations where channel organization and available space are tightly controlled.
Optical engine → front panelOCS / OXC & Optical Backplanes
Organize a predefined optical path matrix inside switching or cross-connect equipment while keeping the approved port map as the governing design record.
Port matrix → fixed routeAI & HPC Network Equipment
Support internal high-density fiber management inside switches, servers and optical transport equipment—such as 51.2 T switch line cards and co-packaged optics front panels—not as a blanket replacement for rack-level structured cabling.
Internal equipment routing05 · Quality Control
How Is Optical Flex Circuit Mapping Verified?
A custom assembly needs a controlled inspection plan, agreed before production and tied to the drawing, route table or quality document.
- Visual workmanship and substrate condition
- Dimensions against the approved drawing
- Fiber continuity and channel mapping
- Polarity or pin-out verification
- Insertion loss and return loss when specified
- Connector end-face inspection when applicable
- Label, packaging and traceability checks
- Contractually agreed qualification items
Custom Development Process
From Fiber Map to Production Release
Submit the application package
Send the route map, mechanical envelope, fiber and interface requirements, quantity and qualification conditions.
Engineering feasibility review
Review routing complexity, exits, bend constraints, termination approach and missing information.
Drawing & mapping confirmation
Confirm port IDs, dimensions, tolerances and inspection criteria before design freeze.
Prototype & qualification
Define sample scope and verification items for the approved configuration.
Production release
Release only against the approved drawing, specification, quality plan and commercial terms.
Design Control
What Changes Require a New Engineering Review?
An optical flex circuit is released against a specific route map and mechanical drawing. Recheck feasibility before production when any of the following inputs change:
- Port-to-port mapping, polarity or channel identification
- Substrate outline, keep-out area, mounting point or available equipment space
- Fiber exit position, pitch, lead length or tolerance
- Fiber type, termination, connector orientation or interface
- Bend constraint, optical limit, test wavelength or environmental requirement
Record the change in the controlled drawing or route table so quotation, prototype inspection and production use the same approved revision.
06 · Request for Quotation
What to Send for an Optical Flex Circuit Quote
A generic “send us your requirement” message is not enough. Share the routing logic and mechanical limits so engineering can review feasibility and quote the correct construction.
Email Your Routing PackageMinimum RFQ Package
- Application and equipment location
- Port-to-port routing map or channel matrix
- Fiber count, mode and preferred specification
- Input and output interfaces
- Substrate outline and keep-out areas
- Exit positions, lead lengths and tolerances
- Optical limits and test wavelength
- Prototype and forecast quantity
Best starting file: Port-to-port route matrix + equipment outline drawing
07 · FAQ
Optical Flex Circuit FAQs
Clear answers for early supplier and feasibility evaluation.
What is the difference between an optical flex circuit and a fiber harness?
A conventional harness manages fibers as separate cables or bundled leads. An optical flex circuit arranges multiple paths on a flexible substrate according to an approved layout and mapping, which can simplify routing inside space-constrained equipment.
Is an optical flex circuit the same as an MPO/MTP harness?
No. MPO/MTP describes a multi-fiber connector system, while an optical flex circuit describes how fibers are organized and routed on a flexible substrate. MPO/MTP may be one project-defined termination option, but it does not define the circuit layout.
Can the fibers be routed point-to-point or as a shuffle?
Yes. The requested topology may be point-to-point, fan-out, shuffle or another logical pattern. Feasibility depends on the route map, geometry, exits, bend constraints and termination design.
When is an optical flex circuit not the right routing format?
Use another format when routes must be changed or serviced frequently, when a conventional harness provides enough flexibility, or when a rack-level shuffle box is more appropriate. The decision should follow the equipment envelope and maintenance model.
What fiber count can BWNFiber provide?
Fiber count is project-defined. BWNFiber reviews the route map and mechanical envelope before confirming an achievable construction instead of publishing an unsupported universal limit.
Which fiber types and connectors are available?
Submit the required fiber and interfaces as design inputs. Exact material and termination availability is confirmed during engineering review for the specific project.
Can this product be used in CPO or OXC equipment?
It can be evaluated for internal routing in CPO, OCS/OXC, optical backplane and other high-density equipment. Compatibility and performance must be verified against the specific equipment design.
How is the routing design accepted before production?
Acceptance should reference an approved route table and mechanical drawing. The project documents should identify port relationships, exits, dimensions, tolerances and the agreed mapping, continuity and optical inspection criteria.
What happens if the fiber map or equipment envelope changes?
A change to port mapping, exit location, available space, fiber or termination requirements may affect feasibility and should be reviewed before the drawing is released again. Production should follow the latest approved revision.
What files should I send for a quotation?
Send the port map, mechanical drawing, fiber and interface requirements, lead lengths, optical limits, environmental requirements, quantity and target schedule.
Custom Optical Interconnects
Request an Engineering ReviewTurn Your Fiber Map into a Custom Optical Flex Circuit Design
Share the routing diagram, interface list and available equipment space. BWNFiber will identify missing inputs and review project feasibility.