FTTH Cable Production: Manufacturing Process Explained
Surprising fact: more than seventy percent of U.S. broadband rollouts now use fiber networks that demand high-precision manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment handles complete Fiber cable sheathing line manufacturing, from choosing brand fibers like Fujikura or Corning® SMF-28e to final test reports that deliver 100% QA.
Our drop cable designs fit overhead, underground, and direct-buried installation, with LSZH, polyvinyl chloride (PVC), and PE jacket options and configurations from 1–4 cores. We provide single-mode OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and logo printing.
Automation and high-precision equipment stabilize line speed and keep repeatability high. Typical lead times are four to five days for orders under 100 km and seven to ten days for < 500 km, with an MOQ of 1 km and warranty covering free replacement for confirmed quality issues.
Read on to understand how materials plus testing and support help reduce lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment offers end-to-end manufacturing and lab testing for United States projects.
- A range of jacket options and optical grades support different install environments.
- Automated production lines deliver stable quality and stable optical performance.
- Fast lead times, low MOQ, and brand fiber options help plan procurement reliably.
- Comprehensive test reports and after-sales warranty back product reliability and documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment delivers 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 full QA coverage and complete test reports.
Our lab performs high-temperature, salt-fog, and vibration tests to verify durability. Jacket options include LSZH, PVC, and PE. Designs cover bow-type flat and figure-8/self-supporting styles and use brand fibers such as Fujikura and Corning® SMF-28e.
- Controlled production lines and production checks for fully auditable shipments.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixtures and calibration reduce variability so every cable meets operator standards.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are built around network requirements, combining brand fiber choices with rigorous test routines.
Selecting Optical Fiber and Brands
We match fiber ribbon line to bend radius, loss, and install environment. 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 meet procurement standards.
Strength Member Options
Strength members employ FRP (dielectric) or metallic 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 indoor flame safety, PVC for flexibility, and PE for outdoor UV and moisture resistance. Tight process control of temperature and capstan ratios keeps line speed stable and dimensional tolerances.
| Member | FRP | Metallic Steel |
|---|---|---|
| Use case | Non-conductive runs | Aerial spans, high tensile |
| Advantage | Lightweight, inert | High strength |
| Installer note | Simple terminations | Requires grounding |
In-Process and Final Testing
Inline geometry and concentricity checks operate in-line. Final optical tests confirm attenuation and return loss. Each order includes a 100% test report and lab results from high heat, salt-spray, and vibration trials to qualify field handling and drop terminations.
Typical lead times are under 100 km in 4–5 days and under 500 km in 7–10 days. Material lot records and first-article approvals provide traceability and compliance for U.S. programs.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment provides 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 consistent optical performance.
The bow-type flat drop cable 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 use a support messenger to handle tension. Choose FRP (dielectric) for non-conductive runs or steel wire when bonding/grounding and extra tensile strength are required.
Strength member and core layouts
We provide both dielectric and metallic strength member configurations to meet safety/EMI requirements. Center 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 qualified for mechanical/optical performance before shipment.
| Type | Best use | Strength member | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting | Aerial spans | FRP/Steel | PE |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Flat unitube | Low-count, easy strip | FRP/Steel | LSZH or PE |
Production Assets for Speed and Quality
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment reduce manual handling and increase throughput for patch cord prep.
Our production line integrates automated machines that cut and strip drop patch cords to increase output and cut labor variability.
The CLX-BPO2 auto-stripping machine runs under PLC and photoelectric control. One cycle is ~1.5 s, giving ~20 terminals per minute in production.
Automated Cut/Strip for Drop Cords
The equipment strips LSZH/PVC jackets and trims FRP or steel strength members to precise stub lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and minimize downtime.
PLC & Photoelectric for Precision
PLC logic and photoelectric sensors give exact positioning and closed-loop control. Inline checks feed control charts so operators can correct trends before out-of-control conditions occur.
| Feature | Spec | Benefit |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Materials | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Automated waste ejection and ergonomic feeders keep the line clean.
- Process control plans capture calibration intervals and critical parameters.
- Integrated assets and trained operators support FTTH volume targets without sacrificing accuracy.
CLX-BPO2 auto-stripping machine capabilities in our line
The CLX-BPO2 provides industrial-grade strip/trim to our line, cutting cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output and standardize prep quality. The unit runs at an approximate cycle time of 1.5 seconds, producing around 20 preps per minute in production.
PLC/photoelectric control enable precise detection and repeatable motion. That control keeps strip and stub lengths within tight tolerances.
Throughput & Cycle Time
Typical operation speed is ~1.5 seconds per cycle. This translates to steady throughput under continuous line conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable strip length from 17.5–35.0 mm. Reserved stubs are adjustable from 7.0–11.0 mm to fit common termination hardware.
Cutting FRP/Steel Members
The machine cleanly cuts FRP and steel wire strength elements while protecting adjacent fibers. Customized cutters are available for nonstandard sizes to preserve precision.
- Auto-eject scrap and sensor-triggered start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass simplify cell integration.
- Cylinder-driven motion and closed-loop control boost reliability and lower maintenance interruptions.
| Specification | Rating | Why it matters |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5–35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0–11.0 mm | Meets strength and termination needs |
| Power/Size | 50W @ 110–220V; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes prep so field teams get drop parts install-ready. The CLX-BPO2 supports our lines in meeting volume targets 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 pair concise options with predictable manufacturing windows so your teams receive ready-to-install products.
Choose 1–4 core designs with SM or MM fiber. Options include OS1, OS2, and OM2–OM4 plus G.652D/G.657 variants to align with optics and connector plans.
We Pantone-match sheath colors for quick field identification and consistent asset tags.
Branding and Print Options
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom print legends and logos aid inventory/warranty tracking.
Length options, packaging, and special structures
Standard reel lengths 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 meet span and isolation needs.
| Choice | Common choice | Benefit |
|---|---|---|
| Reel length | 1, 2, or 4 km | Less staging, easier reels |
| Sheath | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Design | Flat bow / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and provides docs that lists final specifications for easy on-site QA.
QA, Testing & Documentation
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 simulate field stresses for indoor/outdoor applications.
Full Test Reports for Every Reel
Every fiber optic cable ships with 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 warranty claims are simple to verify. Documentation follows common customer templates to accelerate approvals and receiving inspection.
- Line checks and final inspection reduce field failures and cut warranty events.
- QA packages include spec confirmation and formatted data for quick review.
- Ongoing trend analysis inform preventive maintenance and raise long-term reliability.
| Test | Purpose | Outcome |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion robustness | Qualified for outdoor use |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
Cost Drivers and Pricing
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 to $1,000 per unit—based on fiber grade, jacket material, reel length, and design structure.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber grade, jacket material, and the structural type chosen for deployment.
Self-supporting designs and steel strength elements increase material/labor. Custom sheath colors/logos/legends add setup time and influence price for short runs.
Order length, volume, and customization impact on price
Longer reels and higher volume orders reduce unit cost. Short runs often include setup charges and higher unit prices.
- Changeovers and special cutters extend lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets across phases.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Fiber grade | Large | Right-size spec to budget |
| Jacket type | Medium | Compare LSZH vs. PE for total cost |
| Length/Volume | Large | Consolidate runs to cut unit cost |
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 windows reduce downtime and control costs 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 < 500 km. We plan capacity to match your rollout 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 hold contingency capacity to pull in critical-path orders.
Why MOQ Matters
The MOQ is 1 km. This reflects setup needs such as wire/die adjustments that consume start-up material and scrap.
We review your length and staging plans to select reels to reduce waste/handling. Staggered batches can balance inventory holding with frequent, smaller deliveries to job sites.
Installation readiness and application scenarios
On-site conditions dictate whether a self-supporting aerial, 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 advises self-supporting designs with correct strength members to manage sag/tension for long-term reliability.
Duct installations work best with low-friction sheaths and crush-resistant builds so pulling does not damage fibers. PE jackets are typical for underground and buried paths where moisture resistance matters.
Direct-buried designs require proper depth control 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 quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware compatibility. Standardized prep from the production line reduces install time and minimizes scrap.
| Deployment | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting, steel or 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 |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at penetrations |
Our approach delivers a consistent installation across indoor outdoor transitions. That leads to fewer callbacks, speeds activations, and reliable field performance for your system.
Comprehensive Support & After-Sales
Our team coordinates testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements capture through approved drawings and pilot 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 test reports and traceability to support QA acceptance.
- 24/7 availability for status and technical support.
- Warranty includes free replacement for confirmed quality issues.
- Schedule coordination for expedites and urgent changes.
- Configuration control so shipped items match agreed specs consistently.
| Support area | Scope | Benefit |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Reduced field issues |
| Testing | Lab trials & 100% test reports | Full traceability |
| Service | Rapid replacement & root-cause | Lower downtime |
Wrap-Up
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
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 robust production line, including CLX-BPO2 prep assets, reduces variability and shortens turnaround. Our equipment set standardize strip and 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 guides scheduling, logistics, and after-sales care so your deployment stays on plan.
Contact 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 service.
