11/11/2025 – Rewinding machine for optical fiber processing
High-speed rewinder
Supertek GmbH has developed the high-speed rewinder, a new key technology for industrial optical fiber production. The system is currently considered the world’s fastest rewinding machine for delicate optical fibers, so Supertek.
High-Speed-Rewinding-Machine for fiber-optic. © Supertek
High-Speed-Rewinding-machine. © Supertek
It combines maximum processing speed with precise control and opens up new possibilities for automated inline processing of demanding specialty fibers, such as functional coatings or laser-based structuring.
While conventional systems reach around 500m/min and exhibit tensile force fluctuations of up to ten percent, the High-Speed Rewinder operates at more than 1,000m/min with a tolerance of less than <1%. A patented tension control system keeps the fiber tension constant even at high accelerations. This makes it possible to reliably carry out even highly sensitive processes such as inline laser inscription of fiber Bragg gratings. At the same time, the technology enables low-loss rewinding of optical fibers. This is a decisive advantage, as it preserves optical quality.
An intelligent real-time control system continuously monitors speed, fiber path, and winding pattern, ensuring reproducible results without reworking. This not only guarantees low-loss rewinding but also opens up new process windows for high-tech applications.
The modular design of the system allows for the integration of additional processing steps such as color coding, functional coating, or laser structuring. In this way, the High-Speed Rewinder surpasses the previous state of the art in terms of speed, control accuracy, flexibility, and degree of automation.
The demand for modern optical fiber systems is growing worldwide. Drivers include digitalization, automation, sensor networks, and quantum technologies. These developments require production systems that combine high functional density with maximum processing speed. The High-Speed Rewinder meets these requirements and offers a scalable platform for industrial applications. The first machines are already in use internationally and are attracting great interest.
Application areas range from optical sensing and medical technology to photonic networks and multicore fibers. Wherever precision, stability, and high throughput are critical, the technology opens up new production pathways. In international publications, the process is aptly referred to as “low-loss rewinding.” This highlights the advantages for high-end applications such as telecommunications or quantum technology.
A current example illustrates the performance: in the image shown, an optical fiber is processed at 1,450m/min with a stable tensile force of 30 cN. The machine meets the key requirements of modern, digitally networked production with intelligent control, automated process monitoring, and integrated remote maintenance.
With the High-Speed Rewinder, Supertek sets new standards in optical fiber processing. The technology combines speed with precision, enables low-loss rewinding, and thus contributes to the advancement of key industries ranging from telecommunications to aerospace and energy technology.
Product samples on Youtube: https://www.youtube.com/user/SupertekGmbH/videos
Supertek GmbH
Nesserlander Strasse 120
26723 Emden/Germany
Contact person is Steve Kocsis
Tel.: +49 4921 93690-27
