Production at Foss
– From concept to fully tested product

Foss has production facilities in both Norway and Slovakia. Here, modern production technology, experienced operators, components from leading manufacturers and our own expertise in termination, assembly, testing and product development come together. The result can be anything from a single custom product to larger production volumes – inspected, documented and tested before delivery.

From concept to series production

One of the strengths of having our own production is flexibility. A project may start with an idea or a requirement that cannot be met by a standard product. Depending on what needs to be developed or customized, the relevant teams at Foss are involved, typically technical engineering, product management and production.

We can develop a prototype, evaluate the solution and then scale production according to the requirement. A production run may consist of a single product, a small custom series or larger volumes.

As long as the solution is technically feasible, we can customize factors including:

• cable type and length
• fiber or copper type
• connector combinations
• breakout and fan-out
• labeling
• combinations of fiber optics, electrical signals and power

For custom products, our technical team is involved to ensure that the solution is feasible and that relevant standards and technical requirements are taken into account.

Fiber, copper and hybrid solutions

Fiber optics has been a central part of Foss since the company was established, but our production today also includes copper and hybrid solutions. We manufacture products including patch cords, pigtails, pre-terminated fiber cables, panels, MPO/MTP solutions, rugged cable assemblies, pre-terminated network cables, customized cable assemblies and wire harnesses.

Different technologies can also be combined in the same solution. This may include products where fiber optics, copper-based signals and power are integrated into a complete cable assembly.

For the customer, this can mean fewer interfaces, simpler installation and one complete solution tailored to the application.

From subsea to space

Production at Foss covers a wide range of applications, from subsea and offshore to industry, defense, data centers and space.

Many of these applications place high demands on material selection, connector technology, mechanical design, testing and documentation. The requirements vary depending on the application, which means that both components and production processes must be adapted to the environment in which the product will be used.

With expertise in fiber optics, copper, hybrid solutions and mechanical production, Foss can develop and manufacture solutions for very different applications, from demanding underwater installations to products intended for use in space.

Quality throughout the production process

Production at Foss is not only about assembling components. It is also about inspection, documentation and consistent quality throughout the entire production process.

Precision in fiber optic production

Manufacturing fiber optic products requires high precision throughout the process. Fiber connectors are polished using precision equipment from manufacturers including Seikoh Giken. After polishing, connector geometry can be inspected using a Data-Pixel interferometer.

The interferometer measures the geometry of the polished end face and is used to verify relevant parameters against requirements in the IEC 61755 series. This means that we can verify more than the optical performance of the connection. The geometry of the connector end face itself can also be inspected.

Inspection and testing at multiple stages

Quality control does not take place only when the product is finished. Each stage of the production process is inspected by the last, and if a deviation is detected, the product is returned before production continues.

A final inspection is also carried out. Everything leaving our factories is checked.

For terminated fiber products, VIAVI MAP 300 is among the platforms used for optical testing, and measurement results are logged.

Copper production also has dedicated test processes. Terminated copper cables undergo electrical testing before delivery.

For product development and solutions with specific environmental requirements, we also have a climatic chamber with a temperature range from −40 to +180 °C.

Standards, certifications and manufacturer approvals

Production at Foss is based on established quality processes and relevant standards. Foss is certified according to ISO 9001 for quality management and ISO 14001 for environmental management.

Our production teams also have competence and certification within IPC/WHMA-A-620, IPC-A-610 and IPC-A-640. These standards cover requirements and acceptance criteria for cable and wire harness assemblies, electronic assemblies, fiber optic cables and hybrid cable assemblies.

For fiber optic products, relevant IEC standards are also applied, including standards used for connector geometry inspection and other parameters in the production process.

Foss has also developed manufacturer-specific expertise and approvals for selected connector systems and technologies. Both Norway and Slovakia hold R&M approval for E-2000™ assemblies. In Slovakia, Foss is also authorized as a QPC Value-Added Reseller for several rugged fiber optic connector systems.

These approvals are supplemented by training and certification related to specialized connector and production systems from other technology manufacturers.

Together with continuous quality control, testing and traceability, this contributes to a controlled and documented production process.

Traceability from production to finished product

For many projects, documentation and traceability are an important part of the delivery. Production processes at Foss are logged, and each operator records the work performed. Products have serial numbers, and measurement results are stored in a database.

This makes it possible to link production information and measurement data to the individual product and retrieve the documentation later if required.

Capacity for both individual products and larger series

With production in both Norway and Slovakia, Foss has the capacity for high volumes of standard terminations as well as more specialized production runs.

At the same time, our production lines are flexible enough to manufacture a single unit when required. This makes it possible to combine production capacity with customization and smaller specialist series.

For the customer, this means that Foss can be a relevant manufacturing partner whether the requirement is a single customized solution or a product that needs to be manufactured in larger quantities.

Specialized expertise for demanding solutions

Some products require specialized equipment, training and approvals. Foss has expertise in the termination and assembly of a wide range of specialized connector systems for applications including industry, offshore and subsea, defense, space and other demanding environments.

This includes connector technologies such as 3M™ EBO, Expanded Beam and D38999-based solutions, as well as more specialized connector solutions that require dedicated processes, equipment or training.

For certain specialized products, cleanroom facilities are also used during assembly.

Our expertise is developed through both practical production experience and training provided by the manufacturers of the components and connector systems we use.

Development, prototyping and mechanical production

When a standard product does not meet the requirement, it may also be necessary to develop mechanical parts or other components. Foss has 3D printers that can be used for prototypes and smaller production runs. This allows an idea to be tested and further developed before potentially moving into regular production.

We also have our own mechanical workshop in Norway, equipped with CNC machinery, milling and turning equipment and an in-house toolmaker. Here, we can manufacture mechanical components, produce moulds for plastic moulding, and manufacture and assemble racks and other mechanical products.

The combination of optical, electrical and mechanical expertise allows several parts of a customized solution to be developed and manufactured in-house.

Components from specialized manufacturers

A Foss product does not necessarily mean that every individual component is manufactured by Foss. We work with specialized manufacturers and use their components and technologies as building blocks in our own products.

These may include optical connectors, ferrules, fiber cable, rugged connector systems and other components from manufacturers including SENKO, US Conec, Seikoh Giken, TE Connectivity, 3M, Amphenol and OCC.

At Foss, the components are selected and configured for the specific solution before the products are terminated, assembled, inspected and tested.

For the customer, the advantage is that the solution is not locked to a single component manufacturer. Foss can select suitable components, configure them correctly and combine them into a fully tested solution.

European manufacturing in
Norway and Slovakia

Foss has production facilities in both Norway and Slovakia. The two production environments share much of the same expertise and manufacturing capabilities, and largely manufacture the same products. This provides flexibility and capacity across both countries.

For our customers, this means access to a European manufacturing partner with expertise in fiber optics, copper and more specialized cable and connector solutions.

From Requirement to Finished Solution

Having our own production means that Foss can become involved early in a project, before every detail of the solution has necessarily been defined. We can contribute with technical assessments, component selection, prototypes, testing and customization before the product moves into production.

Whether the requirement is a single custom product or a series of several thousand units, the objective is the same: to deliver a solution tailored to the application, controlled throughout production and tested before delivery.

Do you have a requirement that cannot be met by a standard product?

Talk to us early in your project. Together, we can look at the components, materials and production methods best suited to the application.

Talk to us about your project →