FTTH Cable Production: How the Manufacturing Process Works
Quick fact: more than 70% of new U.S. broadband builds now rely on fiber networks that demand tight manufacturing control to hit performance targets.
Shanghai Weiye OFC Equipment manages full-cycle Fiber cable sheathing line manufacturing, from selecting brand fibers like Fujikura® or Corning® SMF-28e to complete test reports that deliver 100% QA.
Our FTTH drop designs suit overhead, ducted, and direct-buried installation, with low-smoke zero-halogen (LSZH), PVC, and polyethylene (PE) jacket options and arrangements from 1–4 cores. We supply OS1/OS2 and OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone sheath colors, and logo printing.
Automated machines and high-precision equipment keep line speed steady and keep repeatability high. Typical lead times run 4–5 days for orders < 100 km and 7–10 days for < 500 km, with an min. order of 1 km and warranty for free replacement on quality issues.
Read on to learn how materials, testing, and support help reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment offers complete production and laboratory testing for U.S. deployments.
- A range of jacket options and optical grades support indoor/outdoor environments.
- Automated lines and machines provide stable quality and reliable optical performance.
- Fast lead times, low MOQ, and brand fiber options help plan procurement reliably.
- Complete reports and warranty support product reliability and compliance documentation needs.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment provides customized drop cables with complete test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment pairs purpose-built equipment with tight material control. We offer customized service and products for single-family and MDU rollouts. Every order comes with 100% quality assurance and complete test reports.
Our lab runs high heat, salt-fog, and vibration tests to verify durability. Jacket options include LSZH, PVC, and PE. Designs offer flat bow-type and figure-8/self-supporting styles and support brand fibers such as Fujikura® and Corning SMF-28e.
- Documented line control and in-process checks for auditable shipments.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixturing and calibration reduce variability so every cable meets operator standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, combining brand fiber choices with strict test routines.
Selecting Optical Fiber and Brands
We select fiber draw tower to minimum bend radius, loss, and deployment type. Options include OS1, OS2, OM2–OM4 and ITU-T G.652D, G.657.A1/A2. Brand fibers such as Fujikura® and Corning® SMF-28e are offered to meet procurement standards.
Strength member integration
Strength members use FRP (dielectric) or galvanized steel wire. FRP is ideal where non-conductive runs are required. Steel wire provides tensile strength for longer aerial spans 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 | FRP | Steel wire |
|---|---|---|
| Use case | Non-conductive runs | High-tension aerial runs |
| Key benefit | Lightweight, inert | High strength |
| Installation note | Simple terminations | Requires grounding |
Testing & Verification
Inline geometry and 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-temperature, salt-spray, and vibration tests to confirm handling for drop terminations and field use.
Typical lead times are 4–5 days for < 100 km and 7–10 days for < 500 km. Material lot records and FAI approvals support traceability and compliance for U.S. projects.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment offers a compact portfolio of 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/ducts. It reduces bend loss for simple routing in MDU corridors and hallways.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs include a messenger element to handle tension. Choose FRP (dielectric) for non-conductive runs or steel messenger when bonding/grounding and extra tensile strength are required.
Core Layouts and Strength Members
We offer both dielectric and metallic strength member configurations to meet safety/EMI requirements. Center loose tube and flat unitube types balance crush resistance and compact fiber unit for fast terminations.
Indoor/outdoor jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each series is validated for mechanical/optical performance before shipment.
| Design | Best use | Strength member | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting | Overhead spans | Steel wire or FRP | Polyethylene |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH or PE |
| Unitube flat | Low-count, easy strip | FRP or steel | LSZH/PE |
Production Assets for Speed and Quality
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 raise throughput and cut labor variability.
The CLX-BPO2 automated stripper uses PLC + photoelectric control. One cycle is about 1.5 seconds, giving ~20 terminals per minute in production.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH/PVC jackets and trims FRP or steel strength 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 closed-loop control. Inline checks update SPC charts so operators can adjust drifts before out-of-control conditions occur.
| Feature | Spec | Result |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Materials | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Process control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Automated waste ejection and ergonomic feeders keep the line clean.
- PCPs document calibration and key parameters.
- Integrated assets and trained operators help meet FTTH volume goals without sacrificing accuracy.
CLX-BPO2 Capabilities on Our Line
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, reducing cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to increase throughput and standardize prep quality. The unit cycles in ~1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC/photoelectric control enable precise detection and repeatable motion. 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 normal production conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable jacket 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 adjacent fibers. Custom tooling are available for non-standard cross-sections to preserve precision.
- Automatic waste ejection and sensor-triggered start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight ease integration into workcells.
- Pneumatic cylinders and closed-loop control improve line reliability and lower maintenance interruptions.
| Spec | 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 |
| Stub (B) | 7.0–11.0 mm | Supports termination strength |
| Power/Size | 50W @ 110–220V; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes terminal prep so field teams get drop parts install-ready. The CLX-BPO2 helps our production lines meet volume goals without compromising quality.
Customized specifications to fit 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 receive ready-to-install products.
Choose 1–4 core designs with single-mode or multimode fiber. Options include OS1, OS2, and OM2–OM4 plus G.652D and G.657 variants to align with optics and connector plans.
We match sheath colors to Pantone codes for quick field identification and consistent asset tagging.
Jacket materials, print legends, and branding
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom legends/logos support inventory and warranty tracking.
Put-Ups, Packaging, and Structures
Standard reel lengths are 1 km, 2 km, and 4 km with custom reels and packaging to fit storage/handling. Choose flat bow-type or self-supporting and FRP or steel members to fit span and isolation requirements.
| Choice | Typical | Benefit |
|---|---|---|
| Length | 1, 2, or 4 km | Less staging, easier reels |
| Jacket | LSZH, PE, PVC | Indoor/Outdoor fit |
| Structure | Bow-type / Self-supporting | Flexible routing/span |
As a supplier, Shanghai Weiye aligns runs to your schedule and provides docs that detail final specs for straightforward QA on site.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item ships with recorded acceptance data.
Lab Testing: Heat, Salt Spray & Vibration
Our lab runs elevated-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials/assemblies. These tests recreate field stresses for indoor and outdoor use.
100% test reports for every cable
Every fiber optic cable includes 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
Lot/batch records link tests to reels/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.
- Quality packages include specifications confirmation and formatted test data for quick review.
- Continuous test trends inform preventive maintenance and improve long-term reliability.
| Trial | Why | Result |
|---|---|---|
| High-temperature | Thermal stability | Validated heat endurance |
| Salt-fog | Corrosion robustness | Qualified for outdoor use |
| Vibration | Resistance to vibration | Improved field reliability |
Pricing and cost drivers for FTTH drop cable
Budget planning for a drop starts with fiber and jacket choices and is refined by volume and customization.
Typical prices vary widely—from about $30–$1,000 per unit—based on fiber grade, jacket material, reel length, and structural design.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, jacket material, and the chosen structure for deployment.
Self-supporting designs and steel members raise material and labor input. Custom colors, logos, and print legends add setup and influence price for short runs.
How Volume & Options Affect Cost
Longer put-ups and larger volumes reduce unit cost. Short runs often carry setup fees and higher unit prices.
- Line changeovers and custom tooling extend lead time and add cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets across phases.
| Factor | Price impact | Guidance |
|---|---|---|
| Fiber grade | Large | Right-size spec to budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Length/Volume | High impact | 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 reduce downtime and control costs when a rollout is underway.
Production Windows & Capacity
Typical production windows run 4–5 days for orders under 100 km and 7–10 days for < 500 km. We plan capacity to track your milestones and to keep deliveries on time.
The service team issues production updates and tracking so installation teams know when reels arrive. For tight schedules, we hold contingency capacity to accelerate critical-path orders.
MOQ and Rationale
The MOQ is one kilometer. This reflects setup needs such as wire and jacket die adjustments that consume start-up material and scrap.
We review your put-ups and staging to select reels to reduce waste/handling. Batch releases can balance inventory with frequent, smaller deliveries to job sites.
Where and How to Deploy
On-site conditions determine whether a self-supporting span, duct 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 recommends self-supporting designs with appropriate members to control sag and tension for long-term reliability.
Duct installations perform best with low-friction jackets and crush-resistant constructs so pulling avoids fiber damage. PE jackets are typical 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 optic core over time.
Indoor Riser/Plenum & ONT
Indoor riser/plenum routes favor LSZH jackets to meet flame and smoke rules. Flat drop profiles strip cleanly and present controlled strength stubs for quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding requirements, lightning exposure, and hardware compatibility. Standardized line prep reduces install time and reduces scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Duct | Low-friction jacket, crush resistance | Use pull tape + lubricant |
| Direct-buried | PE with moisture barrier | Follow depth/warning tape codes |
| Interior | LSZH with tight-bend support | Maintain bend radius at penetrations |
Our approach delivers a consistent installation across indoor outdoor transitions. That reduces callbacks, faster activations, and reliable field performance for your system.
End-to-end support and after-sales service
Our team coordinates tests, line schedules, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements capture through approved drawings and pre-production builds. We deliver documentation templates and clear install notes so field crews share a unified plan.
After-sales service includes fast response, RCA, and corrective action. All products ship with full test reports and traceability to support QA acceptance.
- 24/7 availability for status updates and technical guidance.
- Warranty with free replacement if any quality problems are confirmed.
- Coordination of line schedules for urgent changes or acceleration requests.
- Config control so shipped items match agreed specs consistently.
| Support area | Scope | Outcome |
|---|---|---|
| Tech/Eng | Specs + pilots | Fewer field issues |
| QA/Testing | Lab trials & 100% test reports | Full traceability |
| After-sales | Rapid replacement & root-cause | Minimized downtime |
Conclusion
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
We provide custom FTTH drops that combine materials with validated manufacturing and lab tests. Every reel includes a 100% test report and documented lab trials to support U.S. field acceptance.
A robust production line, including CLX-BPO2 prep assets, reduces variability and speeds turnaround. Our equipment and machines standardize strip/stub lengths so installers get consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance design 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 laboratory validation and responsive support.
