What is the recommended lubrication for MPO/MTP polishing?

Water (general usage) Fiber optic polishing fluid like Aluminum Oxide and Silicon Carbide (for better fiber height control) Final polishing liquid like Cerium Oxide and Silicon Dioxide (for Ultra Polishing) Avoid excessive water, as it affects pressure distribution.

Which polishing machines are compatible with MPO/MTP polishing films?

XYT lapping films work with: Domaille NTT-AT / Ipolish machines Seikoh Giken Bulls Hanxin Wekon HUXUE / KL and more polishing machines All standard MPO fixtures

Are the polishing parameters the same for 12F, 24F, 16F, 32F, 48F connectors?

Generally similar, but: Higher fiber counts require stricter geometry control US Conec vs. Generic ferrules may need slight adjustments XYT can provide SOPs matched to connector type and machine model.

What size of lapping film is used for MPO/MTP polishing?

Common sizes: 127 mm (5-inch) discs for polishing machines 8.5×11 sheets for cutting custom sizes 140mm x 50 m for Automatic polishing machine XYT can also provide pre-cut MPO film sets.

How important is end-face geometry for MPO/MTP polishing?

Very important. Correct geometry ensures: Low insertion loss Stable return loss Proper fiber-to-fiber contact Lower risk of connector damage Diamond films help maintain strict end-face geometry.

What is the correct polishing sequence for MPO/MTP connectors?

Common sequence (industry standard): D30 / SC30 / SC15 → SC9 → SC3 → SC1A → Final (CE0.5/SiO₂) Some customers may add intermediate grades depending on ferrule type or height requirements.

Can MPO/MTP polishing increase fiber height?

Yes. Certain films (example: SC1A, SC1B) can slightly increase fiber height if needed. The height gain depends on: Polishing pressure Time Ferrule type Diamond films generally do not increase fiber height.

Can lapping films be used on hard metals like carbide or hardened steel?

Yes. Diamond lapping films (6–30 µm for cutting and 1–0.5 µm for finishing) are specifically designed for very hard materials.

Which abrasive type avoids deep scratches on softer metals?

For aluminum, brass, or copper: Use ALO (Aluminum Oxide) instead of diamond to avoid aggressive cutting. ALO provides a smoother, more controlled finish.

Can lapping films improve roundness or geometry?

Yes. Using rigid-backed films (5 mil PET) with controlled pressure helps: Correct roundness deviations Remove surface waviness Enhance roller uniformity However, geometry correction is limited to surface-level adjustments.

Which abrasive type is best for defect removal on rollers?

For deep scratches, dents, or uneven surfaces: Diamond 30 µm or SiC 30–45 µm Diamond is preferred for hard-coated rollers (e.g., chrome, tungsten carbide).

How do I know when to replace a lapping film?

Replace your film when you see: Reduced cutting speed Visible clogging or loading Uneven polishing marks Scratches or debris trapped on the surface Worn abrasive coating Consistent replacement ensures uniform performance.

What industries commonly use lapping films?

Lapping films are used in: Fiber optic connector polishing (MPO/MTP/LC/SC) Precision metal finishing Electronics & semiconductor components Optical glass & lens manufacturing Hard disk & magnetic head polishing Medical device finishing Aerospace components Automotive precision parts

Can I order custom-sized lapping films?

Yes. XYT offers custom: Sheet sizes (any dimension) Disc diameters Roll width and length Micron sizes and abrasive types Private label packaging

How long does lapping film last?

Film lifetime varies by: Abrasive type Pressure and polishing speed Workpiece material Coolant or lubrication Diamond films typically last longest, followed by ALO and SiC. Final polishing films (CE, SiO₂) may last several cycles depending on workload.

What surface roughness (Ra) can lapping films achieve?

Depending on the micron grade: 30–15 µm: Ra 0.3–0.6 µm 9–6 µm: Ra 0.1–0.2 µm 3–1 µm: Ra 0.03–0.1 µm 0.5 µm: Ra < 0.02 µm 0.1 µm: Mirror finish Ra < 0.01 µm Actual results depend on material hardness and machine parameters.

How do I prevent contamination during polishing?

To avoid scratches and inconsistent surfaces: Store films in sealed bags Keep polishing plates clean Use lint-free wipes Handle films by the edges Do not touch the abrasive surface with bare hands

Are lapping films compatible with coolant or water?

Most films can be used with: Water Polishing lubricants Slurries (depending on the abrasive type) Diamond and ALO films are typically water-friendly, but CE (cerium) films perform best with glass polishing fluid.

Do lapping films produce consistent results?

Yes—precision films are engineered with: Uniform abrasive particle size Controlled coating thickness Even distribution across the entire surface This ensures predictable performance and repeatable surface finish.

Can lapping film be used for manual polishing?

Yes. Lapping film works with both manual polishing blocks and automatic polishing machines. For manual use, films with more flexible backing (3 mil or 5 mil PET) are preferred to maintain consistent pressure.

What is the difference between diamond, SiC, and aluminum oxide lapping films?

Diamond: Highest hardness, fastest cut rate, ideal for ceramics, glass, ferrules, and hard metals. Silicon Carbide (SiC): Sharp and fast, suitable for softer metals and plastics. Aluminum Oxide (ALO): Durable and economical, excellent for general metal polishing and intermediate steps.

What is the difference between lapping film backing types?

PSA (Pressure-Sensitive Adhesive): Peel-and-stick backing for secure bonding. Non-PSA / Plain: For reusable polishing plates with slurry or carrier film. 3-mil or 5-mil PET backing: Adjusts flexibility and rigidity for different applications.

Can lapping film be used for MPO/MTP fiber optic polishing?

Yes. Lapping film is essential for multi-fiber connector polishing. Typical film sequence: 30 µm or 15 µm → 9 µm → 3 µm → 1 µm → CE0.5 Specialty films may be added depending on connector type, ferrule height requirements, or customer standards.

What sizes are available?

XYT lapping films are offered in: Sheets: 4"×6", 6"×6", 8.5"×11", custom sizes Discs: 3", 4", 5", 6", 8", custom diameters Rolls: 114 mm × 50 m / 305 mm × 50 m / customized length

What is the typical lifetime of a lapping film?

Film life depends on abrasive type, pressure, and workpiece hardness. General guidelines: Diamond films: longer life, stable cut SiC and ALO: economical, shorter life Final glass polishing film (CE): multiple uses depending on load & slurry

Can lapping film be reused?

Diamond films: Often reusable if cleaned properly. SiC/ALO films: Generally single-use for consistent quality. CE films: Can be reused until cut rate or finish degrades. Always evaluate under microscope for scratches or loading.

What equipment is lapping film compatible with?

Fiber optic polishing machines (NTT, Seikoh Giken, Domaille, KL-300, etc.) Automated lapping tools Hand lapping stations Precision polishing machines for metal, ceramic, or semiconductor parts

How should lapping film be stored?

Store in a clean, dry environment away from: Dust contamination Direct sunlight Excess humidity Strong chemicals Keep films flat to avoid wrinkles that affect polishing results.

Do you offer custom micron sizes or specialized grades?

Yes. XYT can produce: Custom micron ranges Modified coating weights Special high-cut diamond grades Ultra-uniform films for semiconductor and optical applications OEM private label packaging

What industries use lapping film?

Fiber Optics (MPO/MTP/LC/SC polishing) Optical glass processing Semiconductor wafer edge polishing Hard disk & precision metal finishing Automotive & aerospace components Medical device polishing

How do I choose the right micron size for industrial polishing (Rollers / Metal parts)?

Choosing the correct micron size depends on your required surface finish, material hardness, and whether you are doing stock removal, intermediate polishing, or final finishing. Below is a general guideline widely used in industrial metal and roller polishing workflows. Micron Size Selection Guide 1. Heavy Stock Removal (Defect Removal / Geometry Correction) Use 30–15 µm Removes deep scratches, wear marks, or surface distortion Suitable for hard metals, tool steel, stainless steel, and coated rollers Common products: Diamond 30 µm, SiC 30 µm, ALO 30 µm 2. Intermediate Polishing (Surface Refinement) Use 12–9–6 µm Smooths the surface after coarse polishing Reduces visible scratch patterns Essential before moving to fine finishing Common choices: Diamond 9 µm / 6 µm 3. Fine Polishing (Pre-Final Finish) Use 3–1 µm Produces a uniform, satin-to-semi-mirror surface Removes micro-scratches left by intermediate grades Great for precision metal components and plating preparation

Polishing Stage Micron Size Purpose Coarse 30–15 µm Heavy removal, defect elimination Medium 12–6 µm Scratch reduction, surface leveling Fine 3–1 µm Pre-finish smoothing Final 0.5–0.1 µm Mirror finish, low Ra

How to choose the correct micron size for Industrial polishing?

Ask yourself: 1. What is the current condition of the surface? Deep scratches? → Start with 30–45 µm Light marks only? → Start with 9–6 µm 2. What finish do you need? Functional finish (Ra 0.1–0.2 µm) → End at 1 µm Mirror finish (Ra < 0.05 µm) → End at 0.5 µm or 0.1 µm 3. What is the material hardness? Hard metals (Steel, Carbide): Prefer Diamond Soft metals (Aluminum, Copper): Prefer ALO or SiC to avoid deep scratches

Suggested Polishing Sequence for Metal / Rollers?

A typical industrial metal polishing workflow looks like: 30 µm → 9 µm → 3 µm → 1 µm → 0.5 µm For extremely hard materials (tungsten carbide / hardened steel): 45 µm → 15 µm → 6 µm → 1 µm → 0.25 µm For softer metals (aluminum / brass): 20 µm → 9 µm → 3 µm → 0.5 µm

How do I choose the right micron size for fiber optics LC SC FC ST MU MT MTP MPO?

The micron size determines how much material is removed: 30–15 µm: Heavy stock removal, shaping, or defect removal. 12–6 µm: Mid-range polishing and geometry correction. 3–1 µm: Fine polishing and pre-final finishing. 0.5–0.02 µm: Final finishing, scratch removal, mirror surface.

What materials are used in lapping films?

Lapping films are made using precision-graded abrasive minerals coated onto a high-strength polyester (PET) backing. The most common abrasive materials include: 1. Diamond (D) The hardest and most efficient cutting abrasive Ideal for glass, ceramic, carbide, sapphire, ferrules, and fiber optic connectors Available in micron sizes from 0.1 µm to 60 µm 2. Silicon Carbide (SiC) Sharp, fast-cutting abrasive Best for softer metals, plastics, and general stock removal Common in 15–80 µm grades 3. Aluminum Oxide (ALO / AO) Durable, cost-effective abrasive for metals, plastics, precision parts Used for mid- and fine-polishing Available from 1–30 µm 4. Cerium Oxide (CeO₂ / CE) Specialized abrasive for optical glass and fiber optic final polishing Used in sub-micron grades (0.3–0.5 µm) 5. Silicon Dioxide (SiO₂) / Final Polishing Film Ultra-fine abrasive for super-smooth finishing Used in the final step of optical and precision surface polishing

What is lapping film?

Lapping film is a precision-coated abrasive film used to achieve controlled material removal and fine surface finishing. It provides consistent particle distribution, predictable cut rate, and stable surface quality across optical, electronic, metal, and industrial applications.

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Location: Home > Application > Customer Case Study: Molex, Rosenberger & Sumitomo Electric

Customer Case Study: Molex, Rosenberger & Sumitomo Electric

2026-01-21

Customer Case Study: Molex, Rosenberger & Sumitomo Electric

High-Precision MMC & MPO/MTP Ferrule Polishing with XYT Lapping Films

Industry Background

As global leaders in fiber optic interconnect solutions, Molex, Rosenberger, and Sumitomo Electric serve hyperscale data centers, telecom infrastructure, automotive networks, and high-speed industrial applications.

With the rapid adoption of high-density MMC and MPO/MTP ferrules (16/24/32/48/64/72 fibers), these manufacturers face increasing challenges in:

Fiber height consistency
Core dip control
End-face geometry stability
High-volume, repeatable production
Cost and supply-chain reliability of consumables

To address these challenges, production teams evaluated alternative lapping film systems capable of matching or exceeding the performance of traditional solutions from 3M, SEIKOH GIKEN, ÅngströmLap, and MIPOX.

Challenge

Across multiple production lines, the manufacturers encountered similar technical and operational issues:

Inconsistent fiber height during MMC pre-polishing
Core dip variability affecting insertion loss and return loss
High consumable costs from branded flocked films
Process sensitivity when scaling to 64- and 72-fiber ferrules
Limited flexibility in polishing sequence optimization

A stable, drop-in lapping film solution was required—one that could integrate into existing DI water polishing processes without equipment changes.

XYT Solution Implemented

After qualification trials, the following XYT lapping film sequence was adopted for MMC and MPO/MTP ferrule polishing:

Polishing Sequence

SC15D – 15 µm Silicon Carbide
- Coarse pre-polishing
- Rapid fiber leveling and bulk material removal
SC3D – 3 µm Silicon Carbide
- Fine pre-polishing
- Scratch refinement and surface uniformity
SC1A – 1 µm Silicon Carbide
- Precision fiber height and core dip control
- Critical preparation before final polish
CE0.5B – 0.5 µm Cerium Oxide
- Final polishing
- Optical-grade surface finish

This sequence was validated as a qualified alternative to AO, SiO₂, and CeO₂ flocked films from established suppliers.

Results & Performance Outcomes

Manufacturing Improvements Observed

Improved fiber height consistency across all ferrule counts
Reduced core dip variation, especially on ≥48-fiber MMC ferrules
Cleaner, more uniform end-face finish
Stable polishing behavior across extended production runs
Higher yield rates with fewer rejected connectors

Operational Benefits

No changes required to existing polishing equipment
Compatible with standard DI water polishing
Longer usable film life compared to traditional flocked films
Lower overall consumable cost per connector

Application Scope

MMC ferrules: 16 / 24 / 32 / 48 / 64 / 72 fibers
MPO / MTP connectors
Telecom & data center interconnects
Automotive optical networks
High-speed optical modules

Why Leading Manufacturers Chose XYT

Process consistency at high fiber counts
Reliable replacement for 3M, SEIKOH GIKEN, ÅngströmLap, and MIPOX
Strong control over fiber height and geometry
Flexible formats: sheets, discs, PSA, and OEM customization
Responsive technical support during qualification and ramp-up

Conclusion

Through structured qualification and production validation, Molex, Rosenberger, and Sumitomo Electric successfully implemented XYT SC15D, SC3D, SC1A, and CE0.5B lapping films as part of their advanced MMC and MPO/MTP ferrule polishing processes.

The result was a stable, scalable, and cost-effective polishing solution that meets the demanding requirements of modern high-density fiber optic manufacturing—without compromising optical performance or production efficiency.

About XYT

XYT specializes in high-precision lapping films and polishing solutions for fiber optics, electronics, automotive, and advanced materials industries. Our products are engineered to deliver consistent results, high yield, and reliable performance across global manufacturing environments.

? Contact XYT for sample requests, cross-reference data, or process optimization support.

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