In the current hyper-connected era, the backbone of our digital infrastructure demands constant innovation. As AI workloads multiply and data centres expand, the optical fibre technologies supporting these systems must evolve at an unprecedented pace. The urgent need for high-fibre density solutions that support two mission-critical objectives - high capacity and ultra-low latency - became paramount. Companies at the forefront of innovation, such as Lightera, are shaping the future of network infrastructure with advancements in hollow core fibre, multi-core fibre, and high-density fibre bundles.

Last week at OFC 2025, AusOptic had the opportunity to witness firsthand how Lightera, the newly rebranded OFC and Furukawa Electric company, is positioning itself at the forefront of optical technology.

Lightera’s current projects include:

  • Hollow Core Fibre (HCF) development in collaboration with leading global partners.
  • Multi-Core Fibre (MCF) solutions for both terrestrial and underwater applications.
  • Advancements in high-fibre density cables, including commercial deployments up to 6912 fibres, with plans to exceed this benchmark.

 

Breaking Bandwidth Barriers

Lightera’s impressive showcase presented a comprehensive suite of solutions tailored for 1.6T connectivity and beyond. As a team we were impressed to see the industry taking the next leap forward, rather than a mere incremental improvement.

The timing is particularly critical. With AI model sizes doubling approximately every six months and hyperscalers pushing the boundaries of current interconnect technologies, the industry has been seeking solutions that can scale without necessitating complete infrastructure overhauls.

 

Technical Breakthroughs

Lightera occupied two booths at OFC (2843 and 2843B), showcasing several groundbreaking products:

Firstly, the TruePhase® 125/245 - a mid-temperature, polarisation-maintaining fibre that retains stability even with a tight 5mm bend radius. What makes this particularly valuable is its ability to withstand solder reflow conditions while maintaining optimal performance at 1550 nm. This capability addresses several critical challenges simultaneously for individuals working on high-density photonic integration.

For those focused on co-packaged optics (an increasingly important area as we strive for tighter integration between optical and electrical components), the Micro Connect 125/245 BI PMF offers exceptional performance in the O-band (1310 nm). Its consistent geometry makes it ideal for the precise alignment requirements of V-groove assemblies in chip-to-laser connections.

Perhaps most exciting from a capacity perspective is the AllWave® FLEX 4X Multicore Fibre (MCF). This innovative design incorporates four separate cores in a single fibre using space division multiplexing. The result? Quadruple the bandwidth without increasing the physical footprint. According to Dan Hendrickson, PLM Director at Lightera, “With its excellent attenuation characteristics and industry-leading low adjacent-core crosstalk, we are already working with key customers on adopting this next-generation fibre solution.”

 

FITEL S185EVROF End-View Splicer for Hollow Core Fibre (HCF) Splicing Applications

Coming in 2025, the new FITEL S185EVROF End-View Fusion Splicer with Ring of Fire® (3-electrode) for precise control over Hollow Core Fibre (HCF) and Multicore Fibre (MCF) splicing

 

Solving New Splicing Challenges

One of the most intriguing developments was not only the fibres themselves, but also the tools to work with them. Multi-core and hollow-core fibres present unique splicing challenges that traditional equipment cannot adequately address.

The new FITEL S185EVROF fusion splicer, developed in partnership with Furukawa Electric, combines End View and Ring of Fire® technologies to enable precise, low-loss splicing of these complex fibre architectures. The Ring of Fire® system uses a 3-electrode plasma to provide a more uniform heat zone to get lower losses. With features such as STA2D discharge and 0.1-degree rotational alignment capability, it provides unprecedented control for technicians working with next-generation fibre designs.

These tools are designed to handle the specific challenges of both hollow-core and multi-core fibres. Their key features include:

  • End-face monitoring to assess fibre cleave quality, particularly critical for hollow-core fibre.
  • Rotational alignment using a FAST algorithm, essential for aligning multi-core and hollow-core fibres correctly.
  • Use of the 3-electrode Ring of Fire® system for controlled, high-quality splicing.

Although these advanced diagnostics add slight overhead to the splice time, the actual fusion process remains highly efficient.

 

Efficiency Meets Performance

Lightera has not overlooked sustainability amidst these performance improvements. Their power-saving fibre modes - LPO (5W), LRO (11W), and Retimed (17W) - provide flexible options for balancing energy consumption with performance requirements.

For data centre operators seeking to optimise space efficiency, Lightera has expanded its Rollable Ribbon portfolio with novel 16- and 24-fibre designs and pre-terminated assemblies. These innovations streamline installation for 800G and 1.6T links while minimising the physical footprint necessitated.

Lightera is deeply involved in developing fibre solutions for data centre interconnects and CPO modules, where the requirement to connect tens of thousands of GPUs demands extreme fibre density and compact packaging.

 

Hollow Core Fibre: Realising the Low-Latency Vision

2025 is a breakout year for hollow core fibre. The latest generation of ultra-low-loss fibres has unlocked a range of new, practical applications that are energising the industry. However, manufacturing the fibre is only part of the challenge. Integrating it into networks requires splicing and connectorisation, areas in which Lightera also excels.

Lightera’s approach includes:

  • A comprehensive ecosystem for hollow core fibre, including splicing and connectivity tools.
  • Live deployments of hollow core fibre since 2018, showcasing their real-world experience.
  • Demonstration of the new FITEL S185EDVROF splicer at OFC 2025, designed specifically to improve splicing performance for hollow core fibre in the field.

One of the core advantages of hollow core fibre is its dramatically reduced latency, a critical requirement for AI workloads. For years, the main barrier to widespread adoption was cost, which depended on achieving sufficient volume. That threshold has now been crossed, with multiple manufacturers entering the space and pushing down costs.

 

Multi-Core Fibre: From Concept to Real-World Deployment

David DiGiovanni, Lightera’s Chief Technology Officer, provided insightful commentary on the evolution and growing acceptance of multi-core fibre (MCF) in a recent YouTube interview with Jose Pozo.

Initially considered a niche technology, MCF is now being seriously considered for mainstream applications due to the exponential increase in required fibre density and bandwidth.

Key developments include:

  • Enhanced space efficiency in fibre cables for data centres and centralised optical processing (CPO) environments.
  • Progression from shape sensing to long-haul telecom applications as R&D and test deployments scale up.
  • Cost reductions driven by processing improvements and application-driven demand.

Regarding core counts, DiGiovanni explained that MCF can support between four and sixteen cores, depending on spatial constraints and application needs. While tight bends and small diameters in CPO modules pose engineering challenges, more than eight cores is becoming feasible.

 

Sensing-Enhanced Fibre: Listening to the Environment

One of Lightera’s showcased innovations at OFC 2025 was a standard flexible fibre with enhanced backscattering. This fibre provides a 10 dB improvement in acoustic sensitivity, making it a powerful tool for Distributed Acoustic Sensing (DAS) applications.

Applications include:

  • Oil and gas: Monitoring seismic activity to optimise well yield.
  • Smart Cities: Monitoring Traffic Flow, Civil Infrastructure, and Bridge Integrity

 

Looking Ahead

For AusOptic, OFC 2025 underscored the significance of the synergy between advanced fibre technologies and photonics innovation in shaping the future of AI and network infrastructure. Companies like Lightera, under the Furukawa Electric group, not only address current challenges but also pave the way for next-generation solutions in bandwidth, latency, sensing, and reliability.

Looking ahead to OFC 2026, the roadmap encompasses even denser fibre solutions, enhanced integration, and broader deployment across diverse industries. These advancements are driven by the relentless demands of AI and the promise of a photonics-powered future.