High Volume Custom Fiber Optic Cable Development

From concept to high-volume production — a true engineering partnership

At Coastal Connections, we specialize in partnering with innovative companies to design and manufacture high-performance customized fiber optic cables for demanding applications across space systems, medical devices, quantum computing, and advanced industrial technologies.

Our structured New Product Introduction (NPI) methodology

Using a proven New Product Introduction (NPI) methodology, we help transform complex concepts into robust, scalable manufacturing solutions. Our four-stage process ensures design integrity, manufacturability, and reliability at every volume level:

From a single prototype to over 10,000 cables shipped per month

Coastal Connections has the engineering depth and manufacturing infrastructure to take your custom fiber-optic design all the way to high-volume production.

Our engineering and manufacturing teams work closely with customers from the earliest stages of concept development through full-scale mass production. We are not simply a manufacturer that builds what you send us — we are a long-term engineering partner that helps you get the design right, validate it thoroughly, and scale it reliably.

1

EVT — Engineering Validation Test

Concept validation, early prototyping, and architectural design. We work directly with your engineering team to validate the core fiber architecture, identify optimal materials, connectors, and coatings, and verify optical performance requirements. This is where we understand exactly what your application demands.

2

DVT — Design Validation Test

Design refinement and real-world validation. We optimize the design for reliability, manufacturability, and spec compliance. Testing protocols and quality controls are established. Pilot builds verify consistency. By the end of DVT, your design is fully proven and production-ready.

3

PVT — Production Validation Test

Manufacturing process validation. We confirm that your product can be produced consistently and efficiently at higher volumes while maintaining required optical and mechanical performance. Process documentation, supply chain readiness, and inspection procedures are finalized.

4

MP — Mass Production

Full-scale manufacturing. With advanced assembly capabilities, controlled environments, and rigorous quality systems, we support reliable high-volume production — maintaining the precision required for high-performance fiber optic assemblies at any volume.

A proven partnership: from concept to 10,000 cables per month

One of our most successful manufacturing partnerships demonstrates the power of this approach. For a major advanced-technology customer, our engineering teams worked together for over three years through the EVT and DVT phases — iterating on fiber architecture, coatings, inspection methods, and assembly processes until the design was fully validated.

Once the design was finalized and manufacturing processes were confirmed, the program transitioned into mass production. We now support over 10,000 cables manufactured and shipped per month for this customer.

This collaboration represents a strong example of how deep technical partnership, structured NPI processes, and manufacturing excellence can transform complex prototypes into reliable high-volume production — delivered on time, to spec, every month.

Manufacturing capabilities

Our production facilities and engineering team provide a comprehensive suite of capabilities across the full fiber-optic assembly lifecycle:

Fiber types

Single-mode (SM), polarization-maintaining (PM), multimode (MM), large mode area (LMA), photonic crystal, and mid-IR fibers. Over 100 fiber types stocked.

Connector and ferrule options

Commercial connectors including FC, LC, SC, SMA, ST, E-2000, Duplex LC IP-68. Defense connectors including 38999, 28876, ARINC 801. Ferrules from 1.25mm to 3.2mm OD in stainless steel and ceramic.

Assembly and cabling

Single and multi-fiber cable assemblies in PVC, PVDF, PTFE, ETFE, LSZH, stainless steel, silicone, and other cabling materials. Fibers installed in plastic or steel cabling up to 100 meters. Matched optical path length assemblies to +/-20ps time delay.

Precision manufacturing technologies

Fiber end-cap installation. PM fiber alignment relative to stress rods. Multi-fiber ferrule assembly. Multi-core fiber alignment. Vacuum feedthrough manufacturing. Precision length control from sub-millimeter to 100+ meter cables.
Coastal Connections - More Than Capable

Quality and testing

Interferometric testing, insertion loss, return loss, polarization extinction ratio (PER) at multiple wavelengths, beam profile analysis, fiber eccentricity, thermal cycling from -65 to 150°C, and visual inspection up to 1,000X magnification.

Supply chain and inventory management

International and domestic sourcing. JIT (just-in-time) stocking programs. Inventory management for ferrite cores, permanent magnets, and fiber optic assemblies. Custom kitting, gapping, grinding, and coating services.

Production capability summary

Capability	Detail
NPI stages	EVT, DVT, PVT, and MP — full lifecycle support from concept to high-volume production
Volume capability	Single prototypes through 10,000+ units per month
Development timeline	Multi-year partnership capability with iterative design refinement
Industries served	Space systems, medical devices, quantum computing, defense, industrial automation
Fiber types	SM, PM, MM, LMA, photonic crystal, mid-IR — 100+ fiber types in stock
Cable length	Up to 100 meters; specialty fibers pulled through jacketing without impractical spool lengths
Thermal testing	In-house thermal cycling -65 to 150°C; extreme environments via Experior Labs
Quality systems	Stringent termination procedures exceeding industry standards; full traceability
Certifications	Products built to defense, space, and medical quality requirements
Supply chain	Domestic and international sourcing; JIT and stocking programs available

Capabilities & Details

NPI stages

EVT, DVT, PVT, and MP — full lifecycle support from concept to high-volume production

Volume capability

Single prototypes through 10,000+ units per month

Development timeline

Multi-year partnership capability with iterative design refinement

Industries served

Space systems, medical devices, quantum computing, defense, industrial automation

Fiber types

SM, PM, MM, LMA, photonic crystal, mid-IR — 100+ fiber types in stock

Cable length

Up to 100 meters; specialty fibers pulled through jacketing without impractical spool lengths

Thermal testing

In-house thermal cycling -65 to 150°C; extreme environments via Experior Labs

Quality systems

Stringent termination procedures exceeding industry standards; full traceability

Certifications

Products built to defense, space, and medical quality requirements

Supply chain

Domestic and international sourcing; JIT and stocking programs available

Frequently Asked Questions

What is the NPI process for custom fiber optic cables?

The New Product Introduction (NPI) process for custom fiber optic cables typically follows four stages: Engineering Validation Test (EVT), Design Validation Test (DVT), Production Validation Test (PVT), and Mass Production (MP). In EVT, the fiber architecture and design are validated with early prototypes. DVT refines the design for reliability and manufacturability under real-world conditions. PVT confirms the manufacturing process can produce the product consistently at volume. MP is full-scale production. Coastal Connections supports all four stages as a long-term engineering partner.

How long does it take to go from prototype to mass production for fiber optic cables?

The timeline depends heavily on the complexity of the fiber assembly design and the application's performance requirements. For demanding applications — such as advanced photonic systems for quantum computing or space-grade assemblies — the EVT and DVT phases can take one to three years or more of iterative development. Coastal Connections has supported programs where this process ran over three years before transitioning to mass production volumes of 10,000+ units per month.

What volume can Coastal Connections support for custom fiber optic assemblies?

Coastal Connections supports everything from single prototype assemblies through high-volume production. Our largest programs currently ship over 10,000 custom fiber optic cables per month. Our infrastructure, quality systems, and supply chain management are designed to scale with your program from the earliest development stages through sustained commercial production.

What industries does Coastal Connections serve for custom fiber optic manufacturing?

Coastal Connections manufactures custom fiber optic assemblies for space systems, medical devices, quantum computing platforms, defense applications, LiDAR systems, laser communications, and advanced industrial automation. Our engineering team has deep experience in the specific performance requirements, testing standards, and qualification processes of each of these sectors.

Can Coastal Connections help with fiber optic cable design, or only manufacturing?

Coastal Connections provides full engineering partnership, not just manufacturing. Our team engages from the earliest concept stage, helping to define fiber architecture, select materials and connectors, develop test protocols, and refine designs through validation. We see ourselves as a long-term engineering partner — the manufacturing excellence we deliver is built on the foundation of thorough design and development collaboration.

Ready to start your development program?

Whether you are in the earliest stages of concept exploration or ready to begin EVT, Coastal Connections is ready to be your fiber optic engineering partner. Let's talk about your application, your timeline, and how we can help you move from concept to volume production with confidence.

(805) 644-5051

2085 SPERRY AVENUE SUITE B
VENTURA, CA 93003