FTTH Cable Production: How the Manufacturing Process Works
Did you know: more than seventy percent of new U.S. broadband builds now use fiber networks that need precise manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment runs complete compact fiber unit manufacturing, from sourcing brand fibers like Fujikura or Corning SMF-28e to complete test reports that guarantee full quality assurance.
Our FTTH drop designs are built for overhead, ducted, and direct burial installation, with low-smoke zero-halogen (LSZH), PVC, and PE jacket options and core counts from 1 to 4 cores. We supply OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automation and precision equipment stabilize line speed and repeatability high. Typical lead times are 4–5 days for orders < 100 km and seven to ten days for < 500 km, with an min. order of 1 km and warranty for free replacement on quality issues.
Continue to understand how materials plus testing and support work together to reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment provides complete production and laboratory testing for U.S. deployments.
- Multiple jacket choices and fiber grades fit different install environments.
- Automated lines and machines ensure consistent quality and stable optical performance.
- Fast lead times, low MOQ, and brand fiber options support reliable procurement planning.
- Complete reports and warranty back product reliability and documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment delivers customized drop cables with full test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment combines specialized equipment with tight material control. We provide customized service and products for residential and MDU rollouts. Every order comes with full QA coverage and full test reports.
Our lab runs high heat, salt spray, 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.
- Documented line control and production checks for auditable shipments.
- Engineering support for specification reviews, trials, and volume ramp.
- 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, pairing brand fiber choices with disciplined test flows.
Selecting Optical Fiber and Brands
We select fiber ribbon line to bend radius, attenuation, and deployment type. Options include OS1/OS2 and 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 integration
Strength members employ FRP (dielectric) or metallic steel wire. FRP is ideal where non-conductive runs are required. Steel wire adds tensile strength for long-span aerial runs and grounding needs.
Extrusion & Process Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility and ease of handling, and PE for UV/moisture resistance outdoors. Closed-loop control of extruder temperature and capstan speed keeps line speed stable and dimensional tolerances.
| Member | FRP | Steel wire |
|---|---|---|
| Use case | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Light, non-corrosive | High strength |
| Installer note | Easier terminations | Bonding/grounding required |
Inline and final testing
Inline geometry and concentricity checks operate in-line. Final optical tests verify attenuation and return loss. Each order ships with a full test report and lab results from high heat, salt fog, and vibration tests to qualify field handling and drop terminations.
Typical lead times are under 100 km in 4–5 days and 7–10 days for < 500 km. Lot records and FAI approvals provide traceability and compliance for U.S. projects.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment provides a focused portfolio of drop designs that fit indoor risers and long aerial runs. Each option combines tested materials with field-termination geometry and stable optical performance.
The bow-type flat drop cable keeps a small footprint for risers and conduit. It reduces bend loss for simple routing in MDU corridors and hallways.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs include a support messenger to carry tensile loads. Choose FRP (dielectric) for non-conductive runs or steel wire when bonding/grounding and higher tensile strength are required.
Strength member and core layouts
We provide both dielectric and metallic strength member configurations to match safety and EMI rules. Center loose tube and unitube flat types balance crush resistance and fiber secondary coating line for fast terminations.
Indoor/outdoor jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor UV and moisture resilience. Each series is qualified for mechanical and optical quality before shipment.
| Design | Best use | Strength member | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | Dielectric FRP | LSZH |
| Self-supporting (aerial) | Overhead spans | FRP/Steel | Polyethylene |
| Central loose-tube | Higher fiber counts | FRP | LSZH or PE |
| Flat unitube | Low-count, easy strip | FRP or steel | LSZH/PE |
Equipment Ensuring Quality and Throughput
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for drop patch preparation.
Our production line integrates automated machines that cut/strip drop cords to raise throughput and cut labor variability.
The CLX-BPO2 auto-stripping machine uses PLC + photoelectric control. One cycle is about 1.5 seconds, giving ~20 terminals per minute in production.
Automated Cut/Strip for Drop Cords
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise stub lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and minimize downtime.
Closed-Loop Control for Repeatability
PLC logic and photoelectric sensors give exact positioning and closed-loop control. Inline checks update SPC charts so operators can correct trends before defects grow.
| Item | Spec | Benefit |
|---|---|---|
| CLX-BPO2 | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Materials | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic loading maintain clean workcells.
- PCPs document calibration and key parameters.
- Integrated assets and trained operators help meet FTTH volume goals without compromising accuracy.
CLX-BPO2 Capabilities on Our Line
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, reducing cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment deploys the CLX-BPO2 to increase throughput and standardize terminal quality. The unit cycles in ~1.5 seconds, producing around 20 preps per minute in production.
PLC/photoelectric control enable precise detection and repeatable actuation. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Cycle time and throughput
Typical operation speed is ~1.5 seconds per cycle. This enables steady throughput under normal production conditions.
Supported jacket and reserved strength 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.
Handling FRP and steel wire strength members
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Custom tooling are offered for nonstandard sizes to preserve precision.
- Automatic waste ejection and sensor-triggered start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass ease integration into workcells.
- Pneumatic cylinders and PLC/photoelectric control improve line reliability and lower maintenance interruptions.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5–35.0 mm | Fits common connector processes |
| 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 terminal prep so field teams get drop parts install-ready. The CLX-BPO2 supports our lines in meeting volume targets without compromising quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures each build to meet your network requirements and simplify field rollout. We combine focused options with predictable schedules so your teams receive ready-to-install products.
Choose 1–4 core designs with SM or MM fiber. Options include OS1/OS2 plus OM2–OM4 along with 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 tags.
Jackets, Legends & Branding
Select LSZH/PVC/PE jackets based on route and safety rules. Custom legends/logos support inventory and 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 flat bow-type or self-supporting and FRP or steel members to fit span and isolation requirements.
| Option | Typical | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and reels |
| Jacket | LSZH / PE / PVC | Indoor/Outdoor fit |
| Structure | Bow-type / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and delivers documentation that lists final specifications for easy on-site QA.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item has recorded acceptance data at ship.
High-temperature, salt spray, and vibration laboratory testing
Our lab runs elevated-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials and assemblies. These tests simulate field stresses for indoor/outdoor applications.
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 prevent nonconforming shipments before they leave the factory.
Traceability 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.
- In-line checks plus final inspection prevent field failures and cut warranty events.
- Quality packages include spec confirmation and formatted test data for rapid review.
- Ongoing trend analysis inform preventive maintenance and improve long-term reliability.
| Trial | Purpose | Result |
|---|---|---|
| High-temperature | Thermal stability | Validated heat endurance |
| Salt spray | Corrosion robustness | Qualified for outdoor use |
| Vibration | Mechanical robustness | Reduced field failures |
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, jacket material, length, and design structure.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber optic 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 influence price for short runs.
Length/Volume/Customization Impact
Longer put-ups and larger volumes lower unit cost. Small quantities often carry setup fees and higher per-unit charges.
- Changeovers and special cutters increase lead time and add to cost.
- Clear RFQs with schedule alignment let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets across phases.
| Driver | Price impact | Recommendation |
|---|---|---|
| Fiber grade | High impact | Balance spec vs. budget |
| Jacket type | Medium | Compare LSZH vs. PE for total cost |
| Length/Volume | Large | Consolidate runs to cut unit cost |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews 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 match your rollout milestones and to keep deliveries on time.
The service team provides updates/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 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 more frequent small-site deliveries.
Installation Scenarios & Readiness
Site conditions dictate whether a self-supporting aerial, ducted pull, or direct-buried run is the best fit for a project.
Deployment Considerations
For aerial runs, Shanghai Weiye OFC Equipment advises 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 builds so pulling does not damage fibers. PE jackets are typical for underground and buried paths where moisture resistance is needed.
Direct-buried designs need correct burial depth per local codes and moisture-resistant jackets 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 cable forms strip cleanly and present controlled strength stubs for fast ONT terminations.
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 | Field note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Duct | Low-friction jacket, crush resistance | Use pull tape + lubricant |
| Direct burial | PE jacket, moisture barrier | Follow local depth and warning tape rules |
| Interior | LSZH with tight-bend support | Maintain bend radius at penetrations |
Our approach delivers a consistent installation across indoor outdoor transitions. That reduces callbacks, speeds activations, and reliable field performance for your system.
Support from Spec to 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 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 covers rapid response, root-cause analysis, and corrective actions. All products ship with full reports and traceability to support QA acceptance.
- Round-the-clock 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.
| Area | What we do | Benefit |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| Testing | Lab + 100% reports | Traceable quality |
| Service | Rapid replacement & root-cause | Minimized downtime |
Conclusion
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
We deliver customized FTTH drop solutions 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, cuts variability and speeds turnaround. Our equipment and machines standardize strip and stub lengths so installers see consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance design and cost to maximize service life. Dedicated support covers scheduling/logistics/after-sales so your deployment stays on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every fiber optic and optic cable shipment with laboratory validation and responsive support.