FTTH Cable Production: Manufacturing Process Explained
Did you know: more than seventy percent of new broadband deployments in the U.S. now use fiber networks that require precise manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment handles complete compact fiber unit manufacturing, from choosing brand fibers like Fujikura or Corning® SMF-28e to final test reports that deliver 100% QA.
Our FTTH drop designs are built for aerial, ducted, and direct-buried installation, with LSZH, PVC, and polyethylene (PE) jacket options and configurations from 1 to 4 cores. We supply single-mode OS1/OS2 and OM2–OM4 grades plus G.652D and G.657 variants, Pantone sheath colors, and logo printing.
Automation and precision equipment stabilize line speed and keep repeatability high. Typical lead times run 4–5 days for orders < 100 km and seven to ten days under 500 km, with an MOQ of 1 km and free-replacement warranty for quality problems.
Continue to understand how materials, testing, and support combine to lower lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment delivers end-to-end manufacturing and lab testing for United States projects.
- Multiple jacket choices and fiber grades support different install environments.
- Automated production lines ensure stable quality and reliable optical performance.
- Quick lead times, low minimums, and brand fiber options help plan procurement reliably.
- Complete reports and warranty support product reliability and compliance documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment provides customized drop cables with complete test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment combines purpose-built equipment with tight material control. We provide customized service and products for residential/MDU deployments. Every order comes with 100% quality assurance and full test reports.
Our lab performs high-temperature, salt spray, and vibration testing to verify durability. Jacket options cover LSZH, PVC, and PE. Designs cover bow-type flat and self-supporting styles and support brand fibers such as Fujikura® and Corning® SMF-28e.
- Controlled production lines and in-process checks for fully auditable shipments.
- Technical support for specs, trials, and ramp to volume.
- Modern fixturing and calibration minimize variation so every cable matches operator specs.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are built around network requirements, combining brand fiber choices with disciplined test flows.
Selecting Optical Fiber and Brands
We match fiber draw tower to minimum bend radius, loss, and deployment type. Options include OS1/OS2 and OM2–OM4 and ITU-T G.652D, G.657.A1/A2. Brand fibers such as Fujikura® and Corning SMF-28e are available to meet procurement standards.
Strength Member Options
Strength members use dielectric FRP or galvanized steel wire. FRP is preferred where non-conductivity is necessary. Steel wire provides tensile strength for long-span aerial runs and grounding needs.
Jacket Options and Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility, and PE for outdoor UV and moisture resistance. Tight process control of extruder temperature and capstan speed stabilizes line speed and dimensional tolerances.
| Component | Dielectric FRP | Metallic Steel |
|---|---|---|
| Primary use | Electrical isolation | High-tension aerial runs |
| Key benefit | Light, non-corrosive | Very high tensile strength |
| Installer note | Easier terminations | Requires grounding |
In-Process and Final Testing
Inline geometry/concentricity checks operate in-line. Final optical tests confirm loss and return loss. Each order ships with a full test report and lab results from high heat, salt-spray, and vibration trials to qualify field handling and drop terminations.
Typical lead times are 4–5 days for < 100 km and 7–10 days for < 500 km. Material lot records and first-article approvals support traceability and compliance for U.S. programs.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment provides a focused portfolio of FTTH drop designs that fit indoor risers and long aerial runs. Each option combines tested materials with field-termination geometry and consistent optical performance.
The bow-type flat drop cable minimizes footprint for risers/ducts. It keeps bend loss low for simple routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs use a messenger element to carry tensile loads. Choose FRP (dielectric) for electrical isolation or steel messenger when bonding/grounding and higher tensile strength are required.
Strength member and core layouts
We provide dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and unitube flat types balance crush resistance and Fiber coloring machine for quick termination.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor UV and moisture resilience. Each family is validated for mechanical/optical performance before shipment.
| Design | Application | Strength member | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting | Aerial spans | FRP/Steel | Polyethylene |
| Center loose tube | Higher-count builds | Dielectric FRP | LSZH or PE |
| Flat unitube | Low count, quick strip | FRP/Steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and increase throughput for drop patch preparation.
Our production line uses automated machines that cut and strip drop patch cords to increase output and reduce operator variability.
The CLX-BPO2 auto-stripping machine uses PLC + photoelectric control. One cycle is ~1.5 s, giving real-world speeds near 20 terminal operations per minute.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH/PVC jackets and trims FRP or steel strength members to precise reserved lengths. Pneumatic cylinder actuators provide quick, repeatable motion and minimize downtime.
Closed-Loop Control for Repeatability
PLC logic + photoelectric sensors give exact positioning and feedback control. Inline checks update SPC charts so operators can adjust drifts before defects grow.
| Item | Capability | Benefit |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Cylinder-based | Fast/reliable motion |
| Materials | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic loading maintain clean workcells.
- PCPs document calibration and key parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without sacrificing accuracy.
CLX-BPO2 auto-stripping machine capabilities in our line
The CLX-BPO2 provides industrial-grade strip/trim to our line, reducing cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output and standardize prep quality. The unit cycles in ~1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC and photoelectric control deliver exact detection and repeatable actuation. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Throughput & Cycle Time
Typical operation speed is 1.5s per cycle. This enables steady throughput under continuous line conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable jacket strip length from 17.5–35.0 mm. Reserved stubs are set between 7.0 and 11.0 mm to match common termination hardware.
FRP & Steel Member Handling
The machine cleanly cuts FRP and steel wire strength elements while protecting neighboring fibers. Custom tooling are available for nonstandard sizes to preserve precision.
- Auto-eject scrap and sensor start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight simplify cell integration.
- Pneumatic cylinders and closed-loop control improve line reliability and lower maintenance interruptions.
| Specification | Rating | Benefit |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5–35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0 to 11.0 mm | Supports termination strength |
| Power/Size | 50W @ 110–220V; 40×18×18 cm | Easy integration into existing equipment |
Using this machine, Shanghai Weiye OFC Equipment standardizes prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 helps our production lines meet volume goals without sacrificing quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures every order to meet your network requirements and simplify deployment. We combine focused options with predictable schedules so your teams receive ready-to-install products.
Choose 1 to 4 cores with SM or MM fiber. Options include OS1/OS2 plus OM2–OM4 plus G.652D/G.657 variants to align with optics and connector plans.
We Pantone-match sheath colors for fast field ID and consistent asset tagging.
Jackets, Legends & Branding
Select LSZH, PVC, or PE jackets based on route and safety rules. Custom legends/logos support inventory and warranty tracking.
Put-Ups, Packaging, and Structures
Standard put-ups are 1 km, 2 km, and 4 km with tailored reels and packaging to fit storage/handling. Choose bow-type flat or self-supporting designs and steel wire or FRP strength members to fit span and isolation requirements.
| Option | Common choice | Advantage |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Less staging, easier reels |
| Jacket | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Design | Bow-type / Self-supporting | Flexible routing/span |
As a supplier, Shanghai Weiye schedules runs to your plan and provides docs that detail final specs for straightforward QA on site.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment builds checkpoints into production so every item has recorded acceptance data at ship.
Lab Testing: Heat, Salt Spray & Vibration
Our lab runs high-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials/assemblies. These tests simulate field stresses for indoor and outdoor use.
100% test reports for every cable
Every fiber optic cable ships with a 100% test report that records loss, return loss, and key geometry where applicable. Final inspection gates stop nonconforming items before they leave the factory.
Audit Trail and Compliance
Batch records tie test data to reels and serials so audits and claims are easy to verify. Documentation follows common customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection reduce field failures and cut warranty events.
- QA packages include specifications confirmation and formatted test data for quick review.
- Continuous test trends inform preventive maintenance and improve long-term reliability.
| Trial | Why | Outcome |
|---|---|---|
| Heat exposure | Thermal stability | Validated heat endurance |
| Salt-fog | Corrosion robustness | Outdoor suitability |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
FTTH Drop Cable Pricing & Cost Drivers
Budget planning for a drop starts with fiber and jacket choices and is refined by volume and customization.
Typical prices range broadly—from about $30–$1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket chemistry (LSZH, PVC, PE), length, and design structure.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber grade, jacket material, and the chosen structure for deployment.
Self-supporting structures and steel members raise material and labor input. Custom colors, logos, and print legends add setup time and impact pricing on small runs.
Length/Volume/Customization Impact
Longer put-ups and larger volumes lower unit cost. Short runs often include setup charges and higher per-unit charges.
- Changeovers and special cutters extend lead time and add cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Driver | Price impact | Guidance |
|---|---|---|
| Optical grade | High impact | Right-size spec to budget |
| Sheath material | Medium | Compare LSZH vs. PE for total cost |
| Order length / volume | Large | Consolidate runs to cut unit cost |
Logistics for the U.S.
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews and sites. Predictable windows cut downtime and help control cost when a rollout is underway.
Scheduling & Capacity Planning
Typical production windows run 4–5 days for orders under 100 km and 7–10 days for orders under 500 km. We schedule line capacity to match your rollout milestones and to maintain on-time delivery.
The service team issues production updates and tracking so installation teams know when reels arrive. For compressed schedules, we reserve contingency capacity to pull in critical-path orders.
Minimum order quantity and why it matters
The MOQ is 1 km. This reflects line setup such as wire and jacket die adjustments that consume start-up material and scrap.
We review your length and staging plans to choose reel sizes that cut waste and handling. Batch releases can balance inventory with frequent, smaller deliveries to job sites.
Installation Scenarios & Readiness
On-site conditions determine whether a self-supporting aerial, ducted pull, or direct burial is the best fit for a project.
Aerial, duct, and direct-buried deployment considerations
For aerial runs, Shanghai Weiye OFC Equipment advises self-supporting designs with correct strength members to manage sag/tension for long-term stability.
Duct installations perform best with low-friction jackets and crush-resistant builds so pulling avoids fiber damage. PE jackets are common for underground and buried paths where moisture resistance is needed.
Direct-buried designs need correct burial depth per local codes and moisture barriers to protect the optic core over time.
Indoor Riser/Plenum & ONT
Indoor riser/plenum routes prefer LSZH to meet flame and smoke rules. Flat drop cable forms strip clean and present controlled strength stubs for quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding needs, lightning exposure, and hardware compatibility. Standardized line prep reduces install time and minimizes scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Underground duct | Low-friction, crush-resistant | Use pull tape and proper lubricant |
| Direct burial | PE jacket, moisture barrier | Follow depth/warning tape codes |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor/outdoor transitions. That reduces callbacks, speeds activations, and stable field performance for your system.
Comprehensive Support & After-Sales
Our team coordinates tests, line schedules, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements capture through approved drawings and pre-production builds. We provide doc templates and clear installation notes so field crews share a unified plan.
After-sales service includes fast response, RCA, and corrective action. All products ship with full reports and traceability to support QA acceptance.
- Round-the-clock availability for status and technical support.
- Warranty with free replacement if any quality problems are confirmed.
- Schedule coordination for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed requirements every time.
| Support area | What we do | Benefit |
|---|---|---|
| Tech/Eng | Specs + pilots | Reduced field issues |
| QA/Testing | Lab + 100% reports | Full traceability |
| Service | Rapid replacement & root-cause | Minimized downtime |
Wrap-Up
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
We deliver customized FTTH drop solutions that pair material choices with validated manufacturing and lab testing. Every reel includes a 100% test report and documented trials to support U.S. field acceptance.
A hardened production line, including CLX-BPO2-enabled prep machines, reduces variability and speeds turnaround. Our equipment set standardize strip/stub lengths so installers get consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance performance and cost to maximize service life. Dedicated support guides scheduling, logistics, and after-sales care so your deployment stays on plan.
Contact Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every fiber optic and optic cable shipment with lab validation and responsive service.