Comparison Table of Lapping Films: Choosing the Right Film for Optical Fiber Polishing

Comparison Table of Lapping Films: Choosing the Right Film for Optical Fiber Polishing

Lapping films are precision-coated abrasive materials designed for polishing optical fiber connectors and other delicate surfaces. With a range of abrasive types and micron grades, selecting the right lapping film is crucial for achieving high-quality, consistent results in optical fiber preparation and other high-precision applications.

This article provides an in-depth comparison of lapping films, breaking down their key characteristics, advantages, and ideal applications to help you make the best choice for your polishing process.

What is Lapping Film?

Lapping film is an advanced polishing material typically used in industries that require a highly precise, smooth surface finish. It consists of a flexible polyester backing coated with abrasive particles, such as diamond, aluminum oxide, silicon carbide, cerium oxide, or silicon oxide. The abrasives are graded into various micron sizes, ranging from 0.01 μm to 45 μm, offering different levels of abrasiveness for specific tasks.

The primary use of lapping film is in the polishing of optical fiber connectors (MPO, MTP, LC, SC), but it also finds applications in semiconductor processing, medical device manufacturing, and photonics.

Lapping film Structure

• Base: Polyester film (flexible, durable)

• Abrasives: Diamond, Aluminum Oxide (Al₂O₃), Silicon Carbide (SiC), Cerium Oxide (CeO₂), Silicon Oxide (SiO₂)

• Backing: Available with or without Pressure-Sensitive Adhesive (PSA)

Comparison Table of Lapping Films

To make the selection process easier, here's a comparison table of various abrasive types used in lapping films, along with their key features, advantages, and best-use cases.

Micron Grades of Lapping Film

Lapping films are available in precise grades ranging from 0.01 μm to 45 μm. Each micron size determines the cutting aggressiveness and surface finish quality:

Breakdown of Lapping Film Types

1. Diamond Lapping Film

• Hardness: Diamond is the hardest naturally occurring substance, making it highly effective for polishing very hard materials like zirconia, glass, and ceramics.

• Durability: Diamond lapping films have exceptional durability and can withstand prolonged use.

• Aggressiveness: While it cuts aggressively, its hardness ensures it maintains precision, making it ideal for fine-tuning surfaces to the nano-level.

• Best Applications: Ceramic ferrules, glass fiber, and zirconia polishing.

• Micron Range: 0.1 μm to 30 μm.

2. Aluminum Oxide Lapping Film

• Hardness: Aluminum oxide is a moderately hard material compared to diamond, offering good cutting ability while being less aggressive.

• Durability: This abrasive is more economical and wears out faster than diamond, but it still offers a reasonable lifespan for light to medium polishing.

• Aggressiveness: It offers balanced aggression, making it suitable for general-purpose polishing tasks, including epoxy removal and plastic ferrule polishing.

• Best Applications: Epoxy, soft metals, and plastics.

• Micron Range: 0.3 μm to 30 μm.

3. Silicon Carbide Lapping Film

• Hardness: Silicon carbide is brittle but extremely sharp, making it great for cutting softer materials quickly.

• Durability: While it is less durable than diamond, it still provides a good amount of usage before it needs replacement.

• Aggressiveness: Silicon carbide’s sharp particles make it aggressive and ideal for rough polishing, such as epoxy removal and initial fiber polishing.

• Best Applications: MPO MT ferrule polishing, Epoxy removal, bare fiber polishing, and shaping ferrules.

• Micron Range: 1 μm to 30 μm.

4. Cerium Oxide Lapping Film

• Hardness: Cerium oxide is a soft abrasive compared to diamond and silicon carbide, but it works effectively with glass.

• Durability: It has a moderate durability, but its chemical properties make it particularly effective for glass polishing.

• Aggressiveness: This material is gentle, making it ideal for achieving a high-gloss finish without causing defects.

• Best Applications: Optical glass polishing, photonics, and fine surface finishing.

• Micron Range: 0.5 μm to 3 μm.

5. Silicon Oxide Lapping Film

• Hardness: Silicon oxide is one of the softest abrasives, making it suitable for ultra-fine finishes rather than aggressive cutting.

• Durability: It offers moderate durability and is typically used for final polishing applications.

• Aggressiveness: The particles in silicon oxide are very fine, ideal for achieving extremely smooth, polished finishes on delicate surfaces.

• Best Applications: Final optical polishing, low-loss fiber connectors, and nano-scale finishing.

• Micron Range: 0.01 μm to 0.3 μm.

Application Areas

Conclusion: How to Choose the Right Lapping Film

The choice of lapping film depends on several key factors:

• Material Being Polished: Harder materials like zirconia or glass require diamond films, while softer materials can benefit from silicon carbide or aluminum oxide.

• Finish Requirement: If you're polishing for a high-gloss finish, go for cerium oxide or silicon oxide.

• Process Stage: For rough lapping and epoxy removal, silicon carbide or aluminum oxide works well. For final polishing, opt for diamond or silicon oxide.

• Durability and Cost: If you need a long-lasting solution and are working with hard materials, diamond lapping film is your best bet. For general-purpose polishing, aluminum oxide is a cost-effective choice.

In conclusion, the right abrasive for your lapping film will depend on your polishing application, material hardness, and required finish quality. Always choose according to the micron size that suits your process for the best results.

Need Expert Help?

Contact us for custom lapping film recommendations, bulk orders, or technical guidance for your MTP/MPO polishing process.