FTTH Cable Production: How the Manufacturing Process Works
Did you know: over seventy percent of new broadband deployments in the U.S. now depend on fiber networks that require high-precision manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment manages end-to-end fiber secondary coating line manufacturing, from choosing brand fibers like Fujikura® or Corning® SMF-28e to final test reports that ensure 100% quality assurance.
Our drop cable designs fit overhead, ducted, and direct-buried installation, with LSZH, PVC, and PE jacket options and configurations from 1–4 cores. We supply OS1/OS2 and multimode OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone sheath colors, and logo printing.
Automation and precision equipment keep line speed steady and maximize repeatability. Typical lead times run four to five days for orders under 100 km and 7–10 days under 500 km, with an MOQ of 1 km and warranty for free replacement on quality issues.
Read on to understand how materials, testing, and support help reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment provides full manufacturing with lab validation for U.S. deployments.
- A range of jacket options and fiber grades support different install environments.
- Automated lines and machines provide consistent quality and stable optical performance.
- Fast lead times, low minimums, and brand fiber options support reliable procurement planning.
- Comprehensive test reports and warranty support product reliability and documentation needs.
Expert 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 stringent material control. We provide custom builds and services for residential/MDU deployments. Every order includes 100% quality assurance and full test reports.
Our lab performs high heat, salt spray, and vibration tests to verify durability. Jacket options include LSZH, PVC, and PE. Designs cover flat bow-type and self-supporting styles and support brand fibers such as Fujikura and Corning® SMF-28e.
- Documented line control and production checks for auditable shipments.
- Technical support for specification reviews, trials, and volume ramp.
- Modern fixtures and calibration reduce variability so every cable matches operator specs.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, combining brand fiber choices with disciplined test flows.
Selecting Optical Fiber and Brands
We select fiber draw tower to minimum bend radius, loss, and install environment. Options include OS1, OS2, OM2–OM4 and G.652D and G.657.A1/A2 per ITU-T. 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 adds tensile strength for long-span aerial runs and grounding needs.
Jacket extrusion and process control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility and ease of handling, and PE for UV/moisture resistance outdoors. Tight process control of temperature and capstan ratios stabilizes line speed and dimensional tolerances.
| Member | FRP | Metallic Steel |
|---|---|---|
| Use case | Non-conductive runs | High-tension aerial runs |
| Advantage | Lightweight, inert | High strength |
| Installation note | Simple terminations | Requires grounding |
In-Process and Final Testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests verify loss and return loss. Each order ships with a 100% test report and lab results from high-temperature, salt fog, and vibration trials to confirm handling for drop terminations and field use.
Typical lead times are under 100 km in 4–5 days and under 500 km in 7–10 days. Material lot records and FAI approvals support traceability and compliance for U.S. projects.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment offers a compact portfolio of FTTH drop designs that cover tight indoor routes and exposed aerial spans. Each option pairs tested materials with geometry tuned for field termination and stable optical performance.
The flat bow-type drop keeps a small footprint for risers and conduit. It reduces bend loss for simple routing in hallways and MDUs.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs include a messenger element to carry tensile loads. Choose FRP (dielectric) for electrical isolation or steel messenger when bonding/grounding and extra tensile strength are required.
Core Layouts and Strength Members
We provide both dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and unitube flat types balance crush resistance and fiber ribbone line for quick termination.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each family is validated for mechanical and optical quality before shipment.
| Type | Application | Strength member | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting | Overhead spans | FRP/Steel | Polyethylene |
| Central loose-tube | Higher fiber counts | FRP | LSZH or PE |
| Flat unitube | Low-count, easy strip | FRP/Steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and boost throughput for drop patch preparation.
Our production line uses automated machines that cut and strip drop patch cords to raise throughput and reduce operator variability.
The CLX-BPO2 automated stripper runs under PLC and photoelectric control. One cycle is about 1.5 seconds, giving real-world speeds near 20 terminal operations per minute.
Automated Cut/Strip for Drop Cords
The equipment strips LSZH and PVC jackets and trims FRP/steel members to precise stub lengths. Cylinder-driven actuators provide quick, repeatable motion and low downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors give exact positioning and feedback control. Inline checks update SPC charts so operators can adjust drifts before out-of-control conditions occur.
| Item | Capability | Benefit |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | High throughput |
| Drive | Pneumatic cylinders | High speed and reliability |
| Materials | LSZH & PVC; FRP & steel | Clean, accurate preps |
| 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 compromising accuracy.
What the CLX-BPO2 Adds
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, cutting cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to increase throughput and standardize prep quality. The unit runs at an approximate cycle time of 1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC/photoelectric control enable precise detection and repeatable actuation. That control keeps strip and stub lengths within tight tolerances.
Line Speed
Typical operation speed is ~1.5 seconds per cycle. This translates to steady throughput under continuous line conditions.
Jacket Strip & Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable strip length from 17.5 to 35.0 mm. Reserved strength member stubs are adjustable from 7.0–11.0 mm to match common termination hardware.
FRP & Steel Member Handling
The machine cleanly cuts FRP and steel wire strength elements while protecting neighboring fibers. Customized cutters are offered for non-standard cross-sections to maintain precision.
- Automatic waste ejection and sensor-triggered start cut idle time.
- Compact size (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass simplify cell integration.
- Cylinder-driven motion and PLC/photoelectric control boost reliability and reduce maintenance downtime.
| Specification | Value | Benefit |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5–35.0 mm | Compatible with common connectors |
| Reserved stub (B) | 7.0 to 11.0 mm | Supports termination strength |
| Power/Size | 110–220V, 50W; 40×18×18 cm | Easy integration into existing equipment |
Using this machine, Shanghai Weiye OFC Equipment standardizes prep so field teams get drop parts install-ready. The CLX-BPO2 helps our production lines meet volume goals without sacrificing quality.
Custom Specs for Your FTTH System
Shanghai Weiye OFC Equipment configures each build to meet your network requirements and simplify deployment. We pair concise options with predictable manufacturing windows so your teams get install-ready reels.
Choose 1 to 4 cores with single-mode or multimode fiber. Options include OS1, OS2, and OM2–OM4 plus G.652D/G.657 variants to match your optics and connector plans.
We Pantone-match sheath colors for fast field ID and consistent asset tagging.
Jacket materials, print legends, and branding
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom print legends and logos aid inventory/warranty tracking.
Lengths, Packaging & Special Builds
Standard reel lengths are 1/2/4 km with custom reels and packaging to suit storage and handling. Choose bow-type flat or self-supporting designs and steel wire or FRP strength members to fit span and isolation requirements.
| Choice | Common choice | Benefit |
|---|---|---|
| Reel length | 1, 2, or 4 km | Less staging, easier reels |
| Jacket | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Design | Bow-type / Self-supporting | Routing and span flexibility |
As a supplier, Shanghai Weiye aligns runs to your schedule and delivers documentation that detail final specs for straightforward QA on site.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item has recorded acceptance data at ship.
Lab Testing: Heat, Salt Spray & Vibration
Our lab conducts elevated-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials and assemblies. These tests recreate field stresses for indoor/outdoor applications.
Per-Reel 100% Reports
Every fiber optic cable includes a 100% test report that logs attenuation, return loss, and geometry where applicable. Final QC gates prevent nonconforming shipments before they leave the factory.
Traceability and compliance
Lot/batch records tie test data to reels and serials so audits and claims are easy to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection prevent field failures and lower warranty events.
- QA packages include specifications confirmation and formatted test data for rapid review.
- Ongoing trend analysis inform preventive maintenance and improve long-term reliability.
| Test | Purpose | Outcome |
|---|---|---|
| Heat exposure | Material stability | Validated heat endurance |
| Salt spray | Corrosion resistance | Outdoor suitability |
| Vibration | Mechanical robustness | Reduced field failures |
Pricing and cost drivers for FTTH drop cable
Budget planning for a drop begins with fiber/jacket selection and is refined by volume and customization.
Typical prices vary widely—from about $30–$1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket material, reel length, and structural design.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber optic grade, sheath material, and the structural type chosen for deployment.
Self-supporting designs and steel members raise material and labor input. Custom colors, logos, and print legends add setup and impact pricing on small runs.
Order length, volume, and customization impact on price
Longer put-ups and larger volumes lower unit cost. Short runs often carry setup fees and higher unit prices.
- Line changeovers and custom tooling increase lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Driver | Effect on price | Guidance |
|---|---|---|
| Optical grade | Large | Balance spec vs. budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Order length / volume | Large | Consolidate where possible |
Lead times, MOQ, and delivery for the United States
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align staffing and sites. Predictable schedules cut downtime and control costs when a rollout is underway.
Scheduling & Capacity Planning
Typical production windows are 4–5 days for < 100 km and 7–10 days for < 500 km. We plan capacity to match your rollout milestones and to maintain on-time delivery.
The service team provides updates/tracking so installation teams know when reels arrive. For compressed schedules, we reserve contingency capacity to pull in critical-path orders.
MOQ and Rationale
The MOQ is 1 km. This reflects setup needs such as wire/die adjustments that use startup material and generate scrap.
We review your put-ups and staging to select reels to reduce waste/handling. Batch releases can balance inventory with more frequent small-site deliveries.
Installation Scenarios & Readiness
Site conditions determine whether a self-supporting span, ducted pull, or direct-buried run is the best fit for a project.
Aerial, duct, and direct-buried deployment considerations
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with correct strength members to control sag and tension for long-term reliability.
Duct installations perform best with low-friction sheaths and crush-resistant builds so pulling does not damage fibers. PE jackets are common for underground and buried paths where moisture resistance matters.
Direct-buried designs need correct burial depth per local codes and moisture barriers to protect the fiber core long-term.
Indoor riser/plenum distribution and ONT termination
Indoor riser and plenum routes favor LSZH jackets to meet smoke/flame codes. Flat drop profiles strip clean and present controlled strength stubs for fast ONT terminations.
We guide the choice of steel or FRP (dielectric) strength members based on bonding requirements, lightning risk, and hardware compatibility. Standardized line prep shortens install time and reduces scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow local depth and warning tape rules |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That leads to fewer callbacks, faster activations, and reliable field performance for your system.
Support from Spec to Service
Our team coordinates testing, scheduling, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements through approved drawings and pilot builds. We provide doc templates and clear installation notes so field crews work from the same plan.
After-sales service includes fast response, RCA, and corrective action. All products ship with full reports and traceability to help QA acceptance.
- Round-the-clock availability for status updates and technical guidance.
- Warranty with free replacement if any quality problems are confirmed.
- Schedule coordination for expedites and urgent changes.
- Configuration control so shipped items match agreed requirements every time.
| Area | Scope | Outcome |
|---|---|---|
| Engineering | Specs + pilots | Reduced field issues |
| Testing | Lab + 100% reports | Full traceability |
| After-sales | Rapid replacement & root-cause | Lower downtime |
Conclusion
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
We provide custom FTTH drops that pair material choices with validated manufacturing and lab testing. Every reel ships with a 100% test report and documented lab trials to support field acceptance in the United States.
A hardened production line, including CLX-BPO2-enabled prep machines, reduces variability and speeds turnaround. Our equipment set standardize strip and stub lengths so installers get consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance performance and cost to maximize service life. Dedicated customer support covers scheduling/logistics/after-sales so your deployment stays on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with lab validation and responsive service.