FTTH Cable Production: Manufacturing Process Explained
Quick fact: over 70% of U.S. broadband rollouts now use fiber networks that require precise manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment handles end-to-end compact fiber unit manufacturing, from choosing brand fibers like Fujikura or Corning SMF-28e to comprehensive test documentation that deliver 100% QA.
Our FTTH drop designs fit aerial, underground, and direct burial installation, with LSZH, PVC, and polyethylene (PE) jacket options and arrangements from 1 to 4 cores. We offer OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and ITU-T G.657 variants, Pantone sheath colors, and logo printing.
Automated machines and precision equipment keep line speed steady and keep repeatability high. Typical lead times run 4–5 days for orders under 100 km and seven to ten days for < 500 km, with an min. order of 1 km and free-replacement warranty for quality problems.
Read on to learn how our materials, tests, and support help reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment provides end-to-end manufacturing and lab testing for United States projects.
- A range of jacket options and fiber grades fit varied installation environments.
- Automated lines and machines provide stable quality and reliable optical performance.
- Quick lead times, low minimums, and recognized brand fibers keep procurement predictable.
- Comprehensive test reports and warranty support product reliability and compliance documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment provides customized drop cables with full test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment pairs purpose-built equipment with tight material control. We provide customized service and products for single-family and MDU rollouts. Every order includes 100% quality assurance and complete test reports.
Our lab runs high-temperature, salt-fog, and vibration testing to validate durability. Jacket options cover LSZH, PVC, and PE. Designs include flat bow-type and self-supporting styles and support brand fibers such as Fujikura and Corning SMF-28e.
- Documented line control and in-process checks for shipments with audit trails.
- Engineering support for requirements, pilots, and scaling.
- Modern fixturing and calibration reduce variability so every cable meets carrier standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, pairing brand fiber choices with disciplined test flows.
Fiber Selection & Brand Options
We select fiber draw tower to minimum bend radius, attenuation, 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 offered to satisfy sourcing standards.
Strength member integration
Strength members employ FRP (dielectric) or metallic steel wire. FRP is preferred where non-conductivity is necessary. Steel wire provides tensile strength for longer aerial spans 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 outdoor UV and moisture resistance. Closed-loop control of temperature and capstan ratios stabilizes line speed and dimensional tolerances.
| Member | FRP | Metallic Steel |
|---|---|---|
| Use case | Electrical isolation | High-tension aerial runs |
| Advantage | Light, non-corrosive | High strength |
| Installation note | Simple terminations | Bonding/grounding required |
Inline and final testing
Inline geometry/concentricity checks operate in-line. Final optical tests verify loss and reflectance. Each order includes a 100% test report and lab results from high-temperature, salt fog, and vibration tests to qualify field handling and drop terminations.
Typical lead times are 4–5 days for < 100 km and under 500 km in 7–10 days. Lot records and first-article approvals support traceability and compliance for U.S. programs.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment offers a focused 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 bow-type flat drop cable minimizes footprint for risers and conduit. It keeps bend loss low for easy routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs include a support messenger to carry tensile loads. Choose dielectric FRP for non-conductive runs or steel wire when bonding/grounding and higher tensile strength are required.
Core Layouts and Strength Members
We offer dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and unitube flat types balance crush resistance and fiber secondary coating line for fast terminations.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each series is validated for mechanical and optical quality 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 |
| Central loose-tube | Higher-count builds | FRP | LSZH or PE |
| Flat unitube | Low-count, easy strip | FRP/Steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment reduce manual handling and boost throughput for drop patch preparation.
Our production line integrates automated machines that cut/strip drop cords to increase output and reduce operator variability.
The CLX-BPO2 automated stripper runs under PLC and photoelectric control. One cycle is ~1.5 s, giving ~20 terminals per minute in production.
Auto Cut & Strip Capabilities
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise reserved lengths. Pneumatic cylinder actuators provide quick, repeatable motion and low downtime.
Closed-Loop Control for Repeatability
PLC logic and photoelectric sensors deliver precise positioning and closed-loop control. Inline checks update SPC charts so operators can adjust drifts before defects grow.
| Item | Capability | Result |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Drive | Pneumatic cylinders | Fast/reliable motion |
| Materials | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic feeders keep the line clean.
- Process control plans capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without compromising accuracy.
What the CLX-BPO2 Adds
The CLX-BPO2 provides industrial-grade strip/trim to our line, reducing cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output and standardize prep quality. The unit cycles in ~1.5 seconds, producing around 20 preps per minute in production.
PLC/photoelectric control enable precise detection and repeatable motion. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Line Speed
Typical operation speed is 1.5s per cycle. This converts to steady throughput under normal production conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable strip length from 17.5 to 35.0 mm. Reserved stubs are set between 7.0 and 11.0 mm to match common termination hardware.
Cutting FRP/Steel Members
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Custom tooling are offered for non-standard cross-sections to preserve precision.
- Auto-eject scrap and sensor start cut idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass ease integration into workcells.
- Cylinder-driven motion and PLC/photoelectric control boost reliability and lower maintenance interruptions.
| Spec | Value | Benefit |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | Supports high-volume runs |
| Strip lengths (A) | 17.5–35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0 to 11.0 mm | Meets strength and termination needs |
| Power & size | 110–220V, 50W; 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 sacrificing quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures every order to fit your network requirements and simplify field rollout. 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 and G.657 variants to align with optics and connector plans.
We match sheath colors to Pantone codes for fast field ID and consistent asset tags.
Jacket materials, print legends, and branding
Select LSZH, PVC, or PE jackets based on route and safety rules. Custom print legends and logos aid inventory/warranty tracking.
Put-Ups, Packaging, and Structures
Standard reel lengths are 1/2/4 km with tailored reels and packaging to fit storage/handling. Choose bow-type flat or self-supporting designs and FRP or steel members to meet span and isolation needs.
| Option | Common choice | Benefit |
|---|---|---|
| Length | 1, 2, or 4 km | Less staging, easier reels |
| Sheath | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Structure | Bow-type / Self-supporting | Routing and span flexibility |
As a supplier, Shanghai Weiye schedules runs to your plan and provides docs that lists final specifications for straightforward QA on site.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment builds checkpoints into production so every item ships with recorded acceptance data.
Lab Testing: Heat, Salt Spray & Vibration
Our lab runs high-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials and assemblies. These tests recreate field stresses for indoor and outdoor use.
Per-Reel 100% Reports
Every fiber optic cable ships with a 100% test report that records loss, return loss, and key geometry where applicable. Final QC 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 uses standard customer templates to speed approvals and inbound inspection.
- Line checks and final inspection reduce field failures and lower warranty events.
- Quality packages include spec confirmation and formatted data for quick review.
- Ongoing trend analysis inform preventive maintenance and improve long-term reliability.
| Trial | Purpose | Result |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion resistance | Outdoor suitability |
| Vibration | Mechanical robustness | 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 to $1,000 per unit—based on fiber grade, jacket chemistry (LSZH, PVC, PE), reel length, and structural design.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber optic grade, sheath material, and the chosen structure for deployment.
Self-supporting designs and steel strength elements increase material/labor. Custom colors, logos, and print legends add setup time and influence price for short runs.
Length/Volume/Customization Impact
Longer put-ups and larger volumes reduce unit cost. Small quantities often include setup charges and higher unit prices.
- Changeovers and special cutters increase lead time and add cost.
- Clear RFQs with schedule alignment let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets across phases.
| Factor | Effect on price | Guidance |
|---|---|---|
| Optical grade | Large | Balance spec vs. budget |
| Sheath material | Medium | Evaluate LSZH vs PE |
| Order length / volume | High impact | Consolidate where possible |
Lead times, MOQ, and delivery for the United States
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews and sites. Predictable windows reduce downtime and control costs when a rollout is underway.
Typical production windows and 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 track your milestones and to keep deliveries on time.
The service team issues production updates and tracking so installation teams can plan arrivals. For tight schedules, we reserve contingency capacity to accelerate 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 use startup material and generate scrap.
We review your length and staging plans to select reels to reduce waste/handling. Batch releases can balance inventory with more frequent small-site deliveries.
Installation readiness and application scenarios
Site conditions determine whether a self-supporting aerial, duct 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 advises self-supporting designs with appropriate members to manage sag/tension for long-term reliability.
Duct installations work 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-resistant jackets to protect the optic core over time.
Indoor riser/plenum distribution and ONT termination
Indoor riser and plenum routes prefer LSZH to meet flame and smoke rules. Flat drop cable forms strip clean and present controlled stubs for quick ONT termination.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning exposure, and hardware compatibility. Standardized prep from the production line reduces install time and minimizes scrap.
| Scenario | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Underground duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct burial | PE with moisture barrier | Follow local depth and warning tape rules |
| Interior | LSZH with tight-bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor/outdoor transitions. That leads to fewer callbacks, speeds activations, and stable field performance for your system.
Support from Spec to Service
Our team coordinates tests, line schedules, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements capture through approved drawings and pilot builds. We deliver documentation templates and clear install notes so field crews work from the same plan.
After-sales service includes fast response, RCA, and corrective action. All products ship with full test reports and traceability to support QA acceptance.
- Round-the-clock availability for status and technical support.
- Warranty includes free replacement for confirmed quality issues.
- Schedule coordination for urgent changes or acceleration requests.
- Config control so shipped items match agreed specs consistently.
| Area | Scope | Outcome |
|---|---|---|
| Tech/Eng | Specs + pilots | Reduced field issues |
| Testing | Lab trials & 100% test reports | Full traceability |
| After-sales | Fast replace + RCA | Lower downtime |
Wrap-Up
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
We deliver customized FTTH drop solutions that combine materials with validated manufacturing and lab tests. Every reel ships with a 100% test report and documented trials to support field acceptance in the United States.
A hardened production line, including CLX-BPO2 prep assets, reduces variability and shortens turnaround. Our equipment set standardize strip and stub lengths so installers see consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance performance and cost to extend service life. Dedicated support guides scheduling, logistics, and after-sales care so your deployment stays on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every fiber optic and optic cable shipment with lab validation and responsive support.