Laser Wire® Systems · Installation
How to Cut & Connect Laser Wire®
Step-by-step guide to cutting Laser Wire® cabling, making FC connections, and setting up your module. Video walkthrough included. Read all safety notes before you start.
Before You Start
Laser Safety
Laser Wire® modules produce laser radiation. Never look directly at an unconnected laser module. Always attach the Laser Wire® cabling to the module before powering it on. Keep the laser aperture pointed away from faces and eyes at all times.
Minimum Bending Diameter
The minimum bending diameter of Laser Wire® cabling is 5mm. Bending past this point will break the glass core. The cable has the consistency of wet spaghetti — use caution when routing around tight corners and always map your path before installing.
Video Walkthrough
Items Required
- Laser Wire® cabling (Super Pop, Pop, or Accent profile)
- Laser Wire® module (Capsule or OpalDrive)
- FC connector housing (comes with module)
- Coupling gel (small dab)
- Power source (5V DC, at minimum 1A)
- Heat shrink tubing (optional — for sealing cut ends)
Step-by-Step Connection
1
Plan Your Route First
Map out the full path of your Laser Wire® cabling before cutting or installing anything. Identify where the module will live and verify no bend in the route will be tighter than 5mm. Routing the cabling after installation is extremely difficult. Use shoelaces or flexible wire to test the path first.
2
Secure the Module Connection Point First
The most common failure point is where the cabling meets the FC connector on the module. Before running the cable, determine where the module will be mounted and secure that connection point. The cable can kink right at the connector boot if the module is under any pressure or weight. Mount the module so there is minimum pressure exerted on the cabling at the connector.
3
Cut the Cabling to Length
Laser Wire® can be cut at any point. The cut end will emit all remaining light energy, making it slightly brighter than the rest of the wire. Depending on your installation, this may or may not be desired. To prevent light spillage at the cut end, you can push the end into an opaque object or apply black heat shrink tubing over the tip.
4
Apply Coupling Gel to the FC Connector Tip
Dab a very small amount of coupling gel onto the ceramic or metal tip of the FC connector. A little goes a long way — less than a drop of water is enough. Coupling gel improves optical efficiency at the glass-to-connector interface. Without it, some light is lost to air gaps and surface imperfections.
5
Attach FC Connector to Module
Screw the FC connector onto the laser module output hand-tight. There is a small slot on the coupler that aligns with the connector for a precision fit. Do not overtighten. Make sure the connection is fully seated before applying power.
6
Connect Power and Test
Connect your module to a 5V DC power source. The light should start right where the FC coupler ends. If the light is dim, check that coupling gel is applied and the connector is fully seated. If there is no light, check polarity on DC connector wires. Verify your power supply can provide at least 1A at 5V (20% more than the module’s rated consumption).
Frequently Asked Questions
Can I cut the cabling to any length?
Yes. The wire will continue to glow up to the point where it is cut. The cut end becomes brighter than other points. You can hide the cut end inside the installation or cap it with black heat shrink.
Do I need one module per cable?
Yes. Each Laser Wire® cable needs its own module. The laser system focuses light down to a 170μm (0.17mm) beam — roughly the diameter of a human hair. Because the coupling is so precise, one module drives one wire. For longer or brighter runs, use DualDrive mode (a module on each end).
What power source works?
Anything that outputs 5V DC at 1A or more: USB wall adapters, power banks, USB ports on computers, or 5V regulated DC supplies. The Capsule module draws under 500mA; most USB sources are sufficient. Size your power supply at 20% above the module’s rated consumption for stable operation.
The light stopped at the connector. What happened?
The cable kinked at the minimum bend diameter, typically right where the connector boot meets the cabling. You will need to make a new connection at the point where the light stopped. See the Patch Cable guide for using an FC coupler to extend a run.
Sewing Into Fabric?
If you are installing into garments or upholstery, see the Welted Profile Installation Guide. The Welted Profile reinforces the cabling for sewing and protects against kinking at stress points.
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