FTTH Cable Production: Step-by-Step Manufacturing Process
Did you know: more than seventy percent of U.S. broadband rollouts now use fiber networks that need tight manufacturing control to achieve required performance.
Shanghai Weiye OFC Equipment runs complete compact fiber unit manufacturing, from sourcing brand fibers like Fujikura® or Corning SMF-28e to final test reports that deliver 100% QA.
Our drop designs fit aerial, ducted, and direct burial installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and polyethylene (PE) jacket options and configurations from 1–4 cores. We provide single-mode OS1/OS2 and OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone sheath colors, and custom logo printing.
Automation and high-precision equipment keep line speed steady and repeatability high. Typical lead times are 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 plus testing and support work together to reduce lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment delivers full manufacturing with lab validation for United States projects.
- A range of jacket options and optical grades cover varied installation environments.
- Automated production lines ensure consistent quality and reliable optical performance.
- Quick lead times, low minimums, and brand fiber options help plan procurement reliably.
- Complete reports and after-sales warranty support product reliability and compliance documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment delivers customized drop cables with complete test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment pairs purpose-built equipment with tight material control. We provide customized service and products for residential and MDU rollouts. Every order comes with 100% quality assurance and full test reports.
Our lab conducts high heat, salt spray, and vibration tests to validate durability. Jacket options include LSZH, PVC, and PE. Designs offer flat bow-type and self-supporting styles and support brand fibers such as Fujikura and Corning SMF-28e.
- Documented line control and production checks for auditable shipments.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixtures and calibration reduce variability so every cable meets carrier standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with rigorous test routines.
Selecting Optical Fiber and Brands
We select FTTH cable production line to minimum bend radius, loss, 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 use FRP (dielectric) or metallic steel wire. FRP is ideal where non-conductive runs are required. Steel wire adds 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 PE for UV/moisture resistance outdoors. Tight process control of extruder temperature and capstan speed stabilizes line speed and dimensional tolerances.
| Component | FRP | Metallic Steel |
|---|---|---|
| Use case | Electrical isolation | High-tension aerial runs |
| Key benefit | Lightweight, inert | Very high tensile strength |
| Installation note | Simple terminations | Bonding/grounding required |
Inline and final testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests confirm attenuation and return loss. Each order ships with a 100% test report and lab results from high-temperature, salt fog, and vibration tests 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. projects.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment offers a compact portfolio of FTTH drop designs that suit both 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/ducts. It reduces bend loss for simple routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs include a messenger element to carry tensile loads. Choose FRP (dielectric) for electrical isolation 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 match safety and EMI rules. Central loose-tube and unitube flat types balance crush resistance and Fiber draw tower for fast terminations.
Indoor/outdoor jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor UV and moisture resilience. Each family is qualified for mechanical and optical quality before shipment.
| Type | Application | Strength element | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | Dielectric FRP | LSZH |
| Self-supporting | Aerial spans | FRP/Steel | Polyethylene |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH or PE |
| Unitube flat | Low-count, easy strip | FRP/Steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and boost throughput for patch cord prep.
Our production line uses automated machines that cut and strip drop patch cords to increase output 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 cutting and stripping for drop cable patch cords
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise reserved lengths. Cylinder-driven actuators deliver fast, repeatable motion and minimize downtime.
Closed-Loop Control for Repeatability
PLC logic + photoelectric sensors deliver precise positioning and closed-loop control. Inline checks update SPC charts so operators can correct trends before defects grow.
| Item | Spec | Result |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Actuation | Cylinder-based | Fast/reliable motion |
| Material handling | LSZH/PVC; FRP/steel | Clean, accurate preps |
| Control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic loading keep the line clean.
- Process control plans document calibration and key parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without sacrificing accuracy.
CLX-BPO2 auto-stripping machine capabilities in 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 uses the CLX-BPO2 to raise output and standardize terminal quality. The unit runs at an approximate cycle time of 1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC/photoelectric control deliver exact detection and repeatable motion. That control keeps strip and stub lengths within tight tolerances.
Throughput & Cycle Time
Typical operation speed is 1.5s 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 jacket strip length from 17.5–35.0 mm. Reserved strength member 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 neighboring fibers. Custom tooling are available for non-standard cross-sections to maintain precision.
- Auto-eject scrap and sensor start cut idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg weight simplify cell integration.
- 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 |
| Jacket strip (A) | 17.5–35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0–11.0 mm | Meets strength and termination needs |
| Power/Size | 50W @ 110–220V; 40×18×18 cm | Easy integration into existing equipment |
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.
Custom Specs for Your FTTH System
Shanghai Weiye OFC Equipment configures every order to fit your network requirements and simplify deployment. 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/G.657 variants to align with optics and connector plans.
We match sheath colors to Pantone codes for fast field ID and consistent asset tagging.
Branding and Print Options
Select LSZH, PVC, or PE jackets to suit route and safety requirements. Custom legends/logos support inventory and warranty tracking.
Put-Ups, Packaging, and Structures
Standard put-ups are 1/2/4 km with custom reels and packaging to suit storage and handling. Choose bow-type flat or self-supporting designs and FRP or steel members to fit span and isolation requirements.
| Option | Common choice | Benefit |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Simpler staging and reels |
| Jacket | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Design | Bow-type / 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.
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 elevated-temperature exposure, salt fog corrosion, and mechanical vibration 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 QC gates prevent nonconforming shipments before they leave the factory.
Traceability & Compliance
Lot/batch records link tests to reels/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.
- Quality packages include spec confirmation and formatted test data for rapid review.
- Ongoing trend analysis drive preventive maintenance and raise long-term reliability.
| Test | Why | Outcome |
|---|---|---|
| High-temperature | Material stability | Validated heat endurance |
| Salt spray | Corrosion robustness | Qualified for outdoor use |
| Mechanical 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 shaped by volume and customization.
Typical prices vary widely—from about $30–$1,000 per unit—based on fiber grade, jacket chemistry (LSZH, PVC, PE), length, and design structure.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, sheath material, and the structural type chosen for deployment.
Self-supporting structures and steel strength elements increase material/labor. Custom sheath colors/logos/legends add setup time and impact pricing on small runs.
How Volume & Options Affect Cost
Longer put-ups and larger volumes lower unit cost. Short runs often carry setup fees and higher per-unit charges.
- Changeovers and special cutters extend lead time and add cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets across phases.
| Driver | Price impact | Guidance |
|---|---|---|
| Fiber grade | High impact | Right-size spec to budget |
| Jacket type | Medium impact | Compare LSZH vs. PE for total cost |
| Length/Volume | High impact | Consolidate runs to cut unit cost |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align staffing and sites. Predictable windows cut 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 orders under 500 km. We plan capacity to match your rollout milestones and to maintain on-time delivery.
The service team provides updates/tracking so installation teams know when reels arrive. For tight schedules, we reserve contingency capacity to pull in critical-path orders.
Minimum order quantity and why it matters
The MOQ is 1 km. This reflects line setup such as wire/die adjustments that use startup material and generate scrap.
We review your length and staging plans to choose reel sizes that cut waste and handling. Staggered batches can balance inventory holding with frequent, smaller deliveries to job sites.
Where and How to Deploy
Site conditions dictate whether a self-supporting aerial, 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 stability.
Duct installations perform best with low-friction jackets and crush-resistant constructs so pulling does not damage fibers. PE jackets are common 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 favor LSZH jackets to meet smoke/flame codes. Flat drop profiles strip clean and present controlled stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware fit. Standardized prep from the production line shortens install time and minimizes scrap.
| Scenario | Key design | Installer note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Underground duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow depth/warning tape codes |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at 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 testing, scheduling, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements through approved drawings and pilot builds. We deliver documentation templates and clear installation 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 includes free replacement for confirmed quality issues.
- Schedule coordination for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed specs consistently.
| Area | Scope | Outcome |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| Testing | Lab trials & 100% test 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 pair material choices with validated manufacturing and lab testing. Every reel includes a 100% test report and documented trials to support field acceptance in the United States.
A robust production line, including CLX-BPO2-enabled prep machines, reduces variability and shortens turnaround. Our equipment set standardize strip/stub lengths so installers get consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance performance and cost to maximize 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 specs, timeline, and volume. We stand behind every fiber optic and optic cable shipment with laboratory validation and responsive service.