FTTH Cable Production: How the Manufacturing Process Works
Quick fact: in excess of seventy percent of new U.S. broadband builds now use fiber networks that require tight manufacturing control to achieve required performance.
Shanghai Weiye OFC Equipment runs end-to-end Fiber cable sheathing line manufacturing, from sourcing brand fibers like Fujikura® or Corning® SMF-28e to comprehensive test documentation that deliver 100% QA.
Our FTTH drop designs fit overhead, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), PVC, and PE jacket options and arrangements from 1 to 4 cores. We offer single-mode OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone sheath colors, and custom logo printing.
Automated machines and high-precision equipment keep line speed steady and maximize repeatability. Typical lead times are 4–5 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 see how materials, testing, and support combine to lower lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment provides end-to-end manufacturing and lab testing for United States projects.
- A range of jacket options and optical grades fit different install environments.
- Automated production lines ensure stable quality and stable optical performance.
- Quick lead times, low MOQ, and brand fiber options help plan procurement reliably.
- Complete reports and warranty back product reliability and compliance 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 pairs purpose-built equipment with stringent material control. We offer customized service and products for single-family and MDU rollouts. Every order includes full QA coverage and complete test reports.
Our lab runs high-temperature, salt spray, and vibration testing 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 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 carrier standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with rigorous test routines.
Optical fiber selection and brand options
We select Fiber coloring machine to bend radius, attenuation, and deployment type. 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 offered to satisfy sourcing standards.
Strength member integration
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 bonding/grounding needs.
Jacket extrusion and 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.
| Component | Dielectric FRP | Metallic Steel |
|---|---|---|
| Primary use | Non-conductive runs | High-tension aerial runs |
| Key benefit | Lightweight, inert | Very high tensile strength |
| Installer note | Simple terminations | Requires grounding |
Testing & Verification
Inline geometry/concentricity checks operate in-line. Final optical tests confirm attenuation and return loss. Each order includes a full test report and lab results from high heat, salt-spray, and vibration trials to confirm handling for drop terminations and field use.
Typical lead times are under 100 km in 4–5 days and 7–10 days for < 500 km. Lot records and FAI approvals support traceability and compliance for U.S. programs.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment provides a compact portfolio of drop designs that cover tight indoor routes and exposed aerial spans. 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/ducts. It keeps bend loss low for easy routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs include a messenger element to handle tension. Choose dielectric FRP for non-conductive runs or steel wire when bonding and extra tensile strength are required.
Strength member and core layouts
We offer dielectric and metallic strength member configurations to match safety and EMI rules. Central loose-tube and unitube flat types balance crush resistance and fiber ribbone line for fast terminations.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor durability. Each family is qualified for mechanical and optical quality before shipment.
| Design | Best use | Strength member | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting (aerial) | Aerial spans | FRP/Steel | PE |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Unitube flat | Low count, quick strip | FRP or steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for patch cord prep.
Our production line integrates automated machines that cut/strip drop 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 ~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 reserved lengths. Cylinder-driven actuators deliver fast, repeatable motion and minimize downtime.
Closed-Loop Control for Repeatability
PLC logic and photoelectric sensors deliver precise positioning and closed-loop control. Inline checks feed control charts so operators can correct trends before defects grow.
| Feature | Spec | Result |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Material handling | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Control | PLC/photoelectric with in-line SPC | Stable quality, reduced 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 sacrificing accuracy.
What the CLX-BPO2 Adds
The CLX-BPO2 provides industrial-grade strip/trim to our line, cutting cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment deploys the CLX-BPO2 to increase throughput 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 and photoelectric control enable precise detection and repeatable motion. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Throughput & Cycle Time
Typical operation speed is ~1.5 seconds per cycle. This translates to steady throughput under normal production conditions.
Jacket Strip & Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable jacket strip length from 17.5–35.0 mm. Reserved stubs are adjustable from 7.0–11.0 mm to fit common termination hardware.
FRP & Steel Member Handling
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Custom tooling are available for nonstandard sizes 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 mass ease integration into workcells.
- Pneumatic cylinders and closed-loop control improve line reliability and reduce maintenance downtime.
| Specification | Rating | Benefit |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Fits common connector processes |
| 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 receive drop parts ready for quick installation. The CLX-BPO2 supports our lines in meeting volume targets without sacrificing quality.
Customized specifications to fit your FTTH system
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, and 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 tagging.
Branding and Print Options
Select LSZH/PVC/PE jackets based on route and safety rules. Custom print legends and logos aid inventory/warranty tracking.
Length options, packaging, and special structures
Standard reel lengths are 1/2/4 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 | Common choice | Advantage |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Simpler staging and reels |
| Sheath | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Structure | Flat bow / Self-supporting | Flexible routing/span |
As a supplier, Shanghai Weiye aligns runs to your schedule and delivers documentation that lists final specifications for straightforward QA on site.
Quality assurance, testing, and documentation
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 high-temperature exposure, salt spray corrosion, and vibration tests to qualify materials/assemblies. These tests simulate field stresses for indoor and outdoor use.
100% test reports for every cable
Every fiber optic cable ships with a 100% test report that logs attenuation, return loss, and geometry where applicable. Final inspection gates stop nonconforming items before they leave the factory.
Audit Trail and Compliance
Batch records link tests to reels/serials so audits and claims are easy to verify. Documentation uses standard customer templates to accelerate approvals and receiving inspection.
- Line checks and final inspection prevent field failures and lower warranty events.
- QA packages include spec confirmation and formatted test data for rapid review.
- Continuous test trends inform preventive maintenance and raise long-term reliability.
| Trial | Purpose | Result |
|---|---|---|
| Heat exposure | Thermal stability | Validated heat endurance |
| Salt spray | Corrosion robustness | Outdoor suitability |
| Mechanical vibration | Resistance to vibration | Reduced field failures |
Pricing and cost drivers for FTTH drop cable
Budgeting for a drop run begins with fiber/jacket selection and is refined by volume and customization.
Typical prices range broadly—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, jacket material, and the structural type chosen for deployment.
Self-supporting designs and steel strength elements increase material/labor. Custom colors, logos, and print legends add setup and impact pricing on small runs.
Length/Volume/Customization Impact
Longer put-ups and larger volumes reduce unit cost. Short runs often carry setup fees and higher unit prices.
- 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 | Guidance |
|---|---|---|
| Optical grade | Large | Balance spec vs. budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Length/Volume | High impact | Consolidate where possible |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align crews and sites. Predictable schedules reduce downtime and help control cost when a rollout is underway.
Production Windows & Capacity
Typical production windows are 4–5 days for < 100 km and 7–10 days for orders under 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 compressed schedules, we reserve contingency capacity to pull in critical-path orders.
Why MOQ Matters
The MOQ is 1 km. This reflects setup needs 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. Staggered batches can balance inventory with frequent, smaller deliveries to job sites.
Installation Scenarios & Readiness
Site conditions determine whether a self-supporting span, ducted 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 advises self-supporting designs with appropriate 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 typical for underground and buried paths where moisture resistance is needed.
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 and plenum routes prefer LSZH to meet flame and smoke rules. Flat drop cable forms strip cleanly and present controlled strength stubs for quick ONT termination.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware compatibility. Standardized prep from the production line reduces install time and reduces scrap.
| Deployment | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct burial | PE with moisture barrier | Follow local depth and warning tape rules |
| Interior | LSZH jacket, tight bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That reduces callbacks, speeds activations, and stable field performance for your system.
Comprehensive Support & After-Sales
Our team coordinates testing, scheduling, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements 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 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.
- Schedule coordination for urgent changes or acceleration requests.
- Config control so shipped items match agreed requirements every time.
| Support area | What we do | Outcome |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Fewer field issues |
| QA/Testing | Lab + 100% reports | Traceable quality |
| 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 deliver customized FTTH drop solutions that combine materials with validated manufacturing and lab tests. Every reel includes a 100% test report and documented trials to support U.S. field acceptance.
A hardened production line, including CLX-BPO2-enabled prep machines, cuts variability and speeds turnaround. Our equipment and machines standardize strip/stub lengths so installers see consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance performance and cost to extend 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 specs, timeline, and volume. We stand behind every shipment with laboratory validation and responsive support.