This paper proposes a symbol-level chaotic masking scheme based on three-dimensional (3D) constellation flip coding. A 3D composite constellation is constructed using regular octagonal diamond shape and regular tetrahedrons as primitive elements. Probabilistic shaping (PS) is introduced to optimize the distribution of constellation points, further enhancing the overall constellation performance. Furthermore, a multi-layer encryption system combining symbol-subcarrier joint perturbation via a 4D multi-phase hyperchaotic system and constellation flip coding encryption is implemented to ensure transmission security. Experimental validation over a 2-km seven-core fiber successfully achieved 59.06 Gb/s orthogonal frequency division multiplexing (OFDM) signal transmission, demonstrating the superior performance of the proposed constellation. At forward error correction (FEC) threshold of 3.8 × 10−3, the receiver sensitivity of the proposed 3D composite constellation exhibited gains of 0.3 dB and 1.21 dB compared to the 32-ary 3D constellation constructed with a regular hexahedron and the traditional 32QAM 2D constellation respectively. Additionally, we achieved a 1.02 dB receiver sensitivity gain at an entropy of 4.4 bits/symbol compared to uniformly distributed constellations. The experimental results also show that the encryption at any layer is breached, the system’s bit error rate (BER) can still reach above 0.5. The encrypted signals showed negligible differences from unencrypted ones, with a key space of 10107 confirming the scheme’s high security and excellent transmission performance. These results highlight its promising potential for future short-reach communication systems.
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