FTTH Cable Production: Step-by-Step Manufacturing Process
Quick fact: in excess of 70% of U.S. broadband rollouts now rely on fiber networks that demand precise manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment manages full-cycle Fiber cable sheathing line manufacturing, from sourcing brand fibers like Fujikura® or Corning® SMF-28e to complete test reports that guarantee full quality assurance.
Our drop cable designs fit overhead, underground, and direct-buried installation, with LSZH, polyvinyl chloride (PVC), and PE jacket options and core counts from 1 to 4 cores. We provide OS1/OS2 and multimode OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone-matched sheath colors, and logo printing.
Automation and precision equipment keep line speed steady and keep repeatability high. Typical lead times run 4–5 days for orders under 100 km and 7–10 days for < 500 km, with an min. order of 1 km and warranty covering free replacement for confirmed quality issues.
Keep reading to see how materials plus testing and support combine to lower lifecycle cost and match the right product to your network system.
- 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 indoor/outdoor environments.
- Automated lines and machines provide consistent quality and stable optical performance.
- Fast lead times, low minimums, and brand fiber options support reliable procurement planning.
- Complete reports and after-sales warranty support product reliability and documentation needs.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment provides tailored drop solutions with full test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment combines specialized equipment with tight material control. We offer custom builds and services for single-family and MDU rollouts. Every order comes with full QA coverage and complete test reports.
Our lab performs high-temperature, salt-fog, and vibration testing to validate durability. Jacket options include 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 production checks for shipments with audit trails.
- 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 disciplined test flows.
Optical fiber selection and brand options
We align fiber draw tower to minimum bend radius, attenuation, and install environment. 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.
Integrating Strength Members
Strength members employ FRP (dielectric) or galvanized steel wire. FRP is preferred where non-conductivity is necessary. Steel wire provides tensile strength for longer aerial spans and bonding/grounding needs.
Jacket Options and Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility, and PE for outdoor UV and moisture resistance. Tight process control of extruder temperature and capstan speed keeps line speed stable and critical dimensions.
| Component | FRP | Metallic Steel |
|---|---|---|
| Use case | Electrical isolation | High-tension aerial runs |
| Key benefit | Light, non-corrosive | High strength |
| Installer note | Easier terminations | Bonding/grounding required |
In-Process and Final Testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests verify attenuation and reflectance. Each order ships with a full test report and lab results from high-temperature, 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 first-article approvals support traceability and compliance for U.S. projects.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment offers 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 consistent optical performance.
The flat bow-type drop keeps a small footprint for risers and conduit. It reduces bend loss for easy routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs use a messenger element to carry tensile loads. Choose FRP (dielectric) for non-conductive runs or steel wire when bonding and higher tensile strength are required.
Core Layouts and Strength Members
We provide both dielectric and metallic strength member configurations to match safety and EMI rules. Central loose-tube and unitube flat types balance crush resistance and compact fiber unit for fast terminations.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor UV and moisture resilience. 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) | Overhead spans | FRP/Steel | PE |
| Center loose tube | Higher-count builds | Dielectric FRP | LSZH or PE |
| Unitube flat | Low-count, easy strip | FRP or steel | LSZH or PE |
Production line equipment that ensures quality and speed
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and boost throughput for drop patch preparation.
Our production line uses automated machines that cut/strip drop cords to raise throughput and cut labor variability.
The CLX-BPO2 auto-stripping machine runs under PLC and photoelectric control. One cycle is ~1.5 s, giving real-world speeds near 20 terminal operations per minute.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH and PVC jackets and trims FRP/steel members to precise reserved lengths. Cylinder-driven actuators provide quick, repeatable motion and low downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors give exact positioning and feedback control. Inline checks update SPC charts so operators can adjust drifts before defects grow.
| Feature | Capability | Result |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Pneumatic cylinders | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Process control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Automated waste ejection and ergonomic feeders maintain clean workcells.
- Process control plans document calibration and key parameters.
- Integrated assets and trained operators help meet FTTH volume goals without compromising 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 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.
Cycle time and throughput
Typical operation speed is 1.5s per cycle. This translates to steady throughput under continuous line conditions.
Supported jacket and reserved strength lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable jacket strip length from 17.5–35.0 mm. Reserved stubs are adjustable from 7.0–11.0 mm to match common termination hardware.
Cutting FRP/Steel Members
The machine cuts FRP/steel strength elements cleanly while protecting adjacent fibers. Customized cutters are offered for non-standard cross-sections to preserve precision.
- Auto-eject scrap and sensor-triggered start cut idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight ease integration into workcells.
- Cylinder-driven motion and PLC/photoelectric control boost reliability and lower maintenance interruptions.
| Spec | Rating | Why it matters |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0–11.0 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 sacrificing quality.
Custom Specs for Your FTTH System
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 to 4 cores with SM or MM fiber. Options include OS1, OS2, and OM2–OM4 along with G.652D/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.
Jackets, Legends & Branding
Select LSZH, PVC, or PE jackets based on route and safety rules. Custom print legends and logos support inventory and warranty tracking.
Put-Ups, Packaging, and Structures
Standard reel lengths are 1/2/4 km with custom reels and packaging to suit storage and handling. Choose bow-type flat or self-supporting designs and steel wire or FRP strength members to meet span and isolation needs.
| Option | Common choice | Benefit |
|---|---|---|
| Length | 1 / 2 / 4 km | Less staging, easier reels |
| Sheath | LSZH, PE, PVC | Indoor/Outdoor fit |
| Structure | Flat bow / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and provides docs that detail final specs for easy on-site QA.
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 elevated-temperature exposure, salt spray corrosion, and vibration tests to qualify materials/assemblies. These tests simulate field stresses for indoor/outdoor applications.
Per-Reel 100% Reports
Every fiber optic cable includes a 100% test report that records loss, return loss, and key geometry where applicable. Final inspection gates prevent nonconforming shipments before they leave the factory.
Traceability & Compliance
Lot/batch records link tests to reels/serials so audits and claims are easy to verify. Documentation follows common customer templates to accelerate approvals and receiving inspection.
- In-line checks plus final inspection prevent field failures and lower warranty events.
- QA packages include spec confirmation and formatted data for rapid review.
- Continuous test trends inform preventive maintenance and improve long-term reliability.
| Test | Purpose | Result |
|---|---|---|
| Heat exposure | Thermal stability | Pass at target temperature |
| Salt spray | Corrosion robustness | Qualified for outdoor use |
| Mechanical vibration | Resistance to vibration | Improved field reliability |
Pricing and cost drivers for FTTH drop cable
Budget planning for a drop begins with fiber/jacket selection and is refined by volume and customization.
Typical prices range broadly—from about $30 to $1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket chemistry (LSZH, PVC, PE), length, and structural design.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, jacket material, and the chosen structure for deployment.
Self-supporting structures and steel strength elements increase material/labor. Custom sheath colors/logos/legends add setup and influence price for short runs.
Length/Volume/Customization Impact
Longer put-ups and larger volumes reduce unit cost. Small quantities often carry setup fees and higher unit prices.
- Line changeovers and custom tooling 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 over phases.
| Driver | Price impact | Guidance |
|---|---|---|
| Fiber grade | High impact | Balance spec vs. budget |
| Jacket type | Medium | Evaluate LSZH vs PE |
| Order length / volume | High impact | Consolidate runs to cut unit cost |
Logistics for the U.S.
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align crews and sites. Predictable schedules 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 reserve contingency capacity to pull in critical-path orders.
Minimum order quantity and why it matters
The MOQ is one kilometer. This reflects line setup such as wire/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 holding with frequent, smaller deliveries to job sites.
Installation Scenarios & Readiness
On-site conditions determine whether a self-supporting span, duct pull, or direct-buried run is the right choice for a project.
Aerial vs Duct vs Direct-Buried
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 perform best with low-friction sheaths and crush-resistant builds so pulling does not damage fibers. PE jackets are common for underground and buried paths where moisture resistance matters.
Direct-buried designs require proper depth control per local codes and moisture-resistant jackets to protect the optic core over time.
Indoor Riser/Plenum & ONT
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 requirements, lightning exposure, and hardware fit. Standardized prep from the production line reduces install time and minimizes scrap.
| Deployment | Key design | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Underground duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct-buried | PE with moisture barrier | Follow depth/warning tape codes |
| Indoor | LSZH with tight-bend support | Maintain bend radius at wall penetrations |
Our approach delivers a consistent installation 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 avoid surprises in deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements through approved drawings and pre-production builds. We provide doc 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 help QA acceptance.
- Round-the-clock availability for status and technical support.
- Warranty with free replacement if any quality problems are confirmed.
- Coordination of line schedules for expedites and urgent changes.
- Config control so shipped items match agreed specs consistently.
| Support area | Scope | Outcome |
|---|---|---|
| Engineering | Spec review & pre-production builds | Fewer field issues |
| QA/Testing | Lab + 100% reports | Traceable quality |
| After-sales | Rapid replacement & root-cause | Minimized downtime |
Wrap-Up
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 ships with a 100% test report and documented lab trials to support field acceptance in the United States.
A hardened production line, including CLX-BPO2-enabled prep machines, reduces variability and shortens 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 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 fiber optic and optic cable shipment with laboratory validation and responsive service.