Abstract: This invention is directed to a optical fiber embedded in a composite material that, prior to installation, is prepared by cleaning, placing end connectors on at least one end and coating with a protective material. The optical fiber is further coated with an X-ray opaque material compatible with the composite material that allows x-rays, during a machining process, to identify the location of optical fiber when embedded in the composite material.

Abstract: An apparatus for providing for the ingress/egress of an optical fiber in composite materials wherein flexible tooling protects the ingress and egress point of the optical fiber. The optical fiber is placed into the uncured laminates of the composite material prior to curing such laminates. The ingress/egress point of this fiber is protected from the laminates by enclosing the fiber with a plurality of polyimide and poly(tetrofluoroethylene) tubes. During the curing process, a rubber plate covers the laminates and the fiber optic lead are brought out of the laminates through a plug in the rubber plate and positioned along the rubber plate in grooves to protect the external fiber leads during curing. After curing a strain relief boot is placed over the fiber optic lead where it ingresses/egresses the composite material to relieve the strain generated on the optical fiber lead during operational use.

Abstract: This invention describes a process for locating the position, orientation d depth of fiber optic sensors embedded in a composite material. The process encompasses the coating of the fiber optic sensor with an X-ray opaque material prior to embedding the sensor in a composite material and then mapping the composite material using radiographic techniques to accurately establish the location, orientation and depth of the sensor. A radiographic film or electronically recorded record of the exact placement of the sensors is prepared that may be referenced during machining operations, correlation of test results and accurate mapping of the structure.