Development and manufacturing of specialty fiber optic cables for oil & gas, monitoring systems and harsh environments
Wires&Bytes GmbH
Berlin (Otto-Suhr-Allee 27, 10585)New on Amplifa
About Wires&Bytes
Wires&Bytes was founded in Berlin in 2019 by industry experts and develops, designs and manufactures specialty fiber optic cables for oil & gas and other harsh environments as well as highly sensitive fiber optic monitoring systems. Manufacturing includes Basic Steel Tubing, Fiber In Metal Tube (FIMT) as well as the encapsulation of optical fiber and copper conductors with various metals, alloys and polymers. The company offers 14 cable designs for monitoring systems and uses a total of around 23,000 m² of manufacturing space in Europe and the USA. The service portfolio includes feasibility studies, prototyping, special and type testing, qualification procedures, on-site testing and measurement as well as after-sales support. Customers include industries such as oil & gas, structural health monitoring (bridges, railways, pipeline leak detection, fire detection, geothermal), industrial sensing, security as well as power and energy distribution. All components are fully traceable and documented.
- Site
- Berlin
- Processes
- Manufacturing of Specialty Fiber Optic Cables (design, development, production), Manufacturing of Basic Steel Tubing (steel tubes), FIMT - Fiber In Metal Tube manufacturing, Encapsulation of optical fiber and copper conductors with metals, alloys and polymers, Prototyping and sampling of cables, Cable testing: water ingress, mechanical tests (tensile performance, crush, repeated bending,, Measurement of mechanical stress and fiber strain in the cable by means of BOFDA/BOFDR, Specification of Brillouin frequency characteristics (Central Brillouin Frequency,
- Materials
- Steel (Steel Tubing), Copper (Copper conductor), Optical fiber, Polymers (encapsulation), Metals and alloys (encapsulation), Steel Tubing, Fiber In Metal Tube, Copper
- Certificates
- 8 in-house test types (mechanical, electrical, temperature, water ingress), BOFDA/BOFDR measurement of stress and fiber strain, Full traceability of all components
- Founded
- 2019
- Employees
- 11-50
- Industries
- Oil & Gas, Structural Health Monitoring, Industrial Sensing, Security, Power and Energy Distribution, Pipeline Monitoring
- 01
Definition of technical requirements / technical documentation
- 02
Feasibility study for new cable designs
- 03
Prototyping
- 04
Manufacturing of Steel Tubing and FIMT
- 05
Encapsulation of optical fiber and copper conductors with metals, alloys,
- 06
In-house testing and qualification procedures
- 07
Testing & measurements at customer sites
- 08
After-sales support
Materials & Processes
Steel Tubing
Steel tubes as the basic component of the cable construction, manufactured in-house.
Fiber In Metal Tube
Optical fiber in a metal tube as the core for fiber optic sensor cables in harsh environments.
Copper
Copper conductors are encapsulated together with optical fiber, e.g. for electrical power supply.
Metals and Alloys
Various metal and alloy configurations for outer encapsulations depending on the application.
Polymers
Polymeric encapsulations to protect the cable core in application-specific designs.
Optical Fiber
Optical fiber as the sensing medium for distributed measurements (including Brillouin-based).
Locations
Berlin
DEHeadquarters / Production
- Lot size
- Prototyping/Sampling up to series volumes
- Materials
- Steel, copper, optical fiber, metals, alloys, polymers
- Dynamic Fatigue Testing Machine (cable bend lifespan testing machine)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacturing of Specialty Fiber Optic Cables (design, development, production)Engineering | – | – | – | Prototyping/Sampling – Series volumes | Steel, Copper, Metals, Alloys, Polymers, Optical fiber |
| Manufacturing of Basic Steel Tubing (steel tubes)Forming | – | – | – | – | Steel |
| FIMT - Fiber In Metal Tube manufacturingJoining | – | – | – | – | Steel, Optical fiber |
| Encapsulation of optical fiber and copper conductors with metals, alloys and polymersSurface | – | – | – | – | Optical fiber, Copper, Metals, Alloys, Polymers |
| Prototyping and sampling of cablesEngineering | – | – | – | – | Optical fiber, Copper, Steel, Polymers |
| Cable testing: water ingress, mechanical tests (tensile performance, crush, repeated bending,Testing | – | – | – | – | Optical fiber, Copper, Steel |
| Measurement of mechanical stress and fiber strain in the cable by means of BOFDA/BOFDRTesting | – | 600 m (measurement distance in diagram) | – | – | Optical fiber |
| Specification of Brillouin frequency characteristics (Central Brillouin Frequency,Testing | – | – | – | – | Optical fiber |
| Feasibility studies and definition of qualification procedures for cable designsEngineering | – | – | – | – | – |
| Testing & measurements at customer sites / installation sitesTesting | – | – | – | – | – |
1 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Dynamic fatigue testing machine (cable bend lifespan testing machine) | – | – | – | – | Wires&Bytes Test center |
Additional services
Quality & Testing
Wires&Bytes performs eight in-house test types, including water ingress, mechanical tests (tensile strength, crush, repeated bending, torsion, impact), electrical tests and temperature tests. With BOFDA/BOFDR, mechanical stress and fiber strain in the cable are measured; the Brillouin frequency characteristics (Central Brillouin Frequency, Strain/Temperature Sensitivity) are specified.
| Evidence | Berlin |
|---|---|
| 8 in-house test types (mechanical, electrical, temperature, water ingress) | |
| BOFDA/BOFDR measurement of stress and fiber strain | |
| Full traceability of all components |
History
- 2019
Foundation of Wires&Bytes in Berlin by industry experts with over 70 years of combined industry experience of the four founding partners
- 2024
Trade fair presence at ADIPEC
- 2025
Trade fair presence at ADIPEC; expansion with a Dynamic Fatigue Testing Machine for predicting cable bend lifespan
- 2026
Trade fair presence at EGYPS