FTTH Cable Production: Step-by-Step Manufacturing Process
Surprising fact: in excess of 70% of new U.S. broadband builds now use fiber networks that need high-precision manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment handles end-to-end fiber secondary coating line manufacturing, from selecting brand fibers like Fujikura or Corning® SMF-28e to final test reports that guarantee full quality assurance.
Our drop cable designs suit aerial, underground, and direct burial installation, with LSZH, PVC, and PE jacket options and core counts from 1 to 4 cores. We provide OS1/OS2 and OM2–OM4 grades plus G.652D and G.657 variants, Pantone sheath colors, and logo printing.
Automated machines and precision equipment keep line speed steady and keep repeatability high. 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 understand how materials, testing, and support work together to reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment provides end-to-end manufacturing and lab testing for U.S. deployments.
- A range of jacket options and optical grades cover indoor/outdoor environments.
- Automated lines and machines deliver stable quality and stable optical performance.
- Quick lead times, low minimums, and brand fiber options keep procurement predictable.
- Complete reports and warranty back product reliability and compliance documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment delivers tailored drop solutions with full test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment combines purpose-built equipment with tight material control. We provide custom builds and services for residential and MDU rollouts. Every order comes with 100% quality assurance and full test reports.
Our lab performs high-temperature, salt spray, and vibration testing to verify durability. Jacket options cover LSZH, PVC, and PE. Designs offer bow-type flat and self-supporting styles and use brand fibers such as Fujikura and Corning SMF-28e.
- Documented line control and in-process checks for fully auditable shipments.
- Technical support for specs, trials, and ramp to volume.
- Modern fixtures and calibration minimize variation so every cable meets operator standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with strict 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 ITU-T G.652D, G.657.A1/A2. Brand fibers such as Fujikura® and Corning SMF-28e are offered to satisfy sourcing standards.
Strength Member Options
Strength members employ dielectric FRP or galvanized 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 ease of handling, and PE for UV/moisture resistance outdoors. Tight process control of temperature and capstan ratios keeps line speed stable and dimensional tolerances.
| Component | Dielectric FRP | Metallic Steel |
|---|---|---|
| Use case | Non-conductive runs | Aerial spans, high tensile |
| Key benefit | Lightweight, inert | High strength |
| Installer note | Easier terminations | Requires grounding |
Inline and final testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests confirm attenuation and return loss. Each order includes a full test report and lab results from high-temperature, salt fog, 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 focused portfolio of FTTH drop designs that fit indoor risers and long aerial runs. Each option combines tested materials with field-termination geometry and stable optical performance.
The flat bow-type drop keeps a small footprint for risers and conduit. It keeps bend loss low for simple routing in hallways and MDUs.
Self-Supporting Aerial Designs
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.
Layouts & Strength Members
We offer dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and flat unitube types balance crush resistance and Fiber draw tower for quick termination.
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/optical performance before shipment.
| Design | Application | Strength member | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | Dielectric FRP | LSZH |
| Self-supporting (aerial) | Overhead spans | FRP/Steel | Polyethylene |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Flat unitube | Low-count, easy strip | FRP/Steel | LSZH/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 and strip drop patch cords to raise throughput and cut labor variability.
The CLX-BPO2 automated stripper 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 and PVC jackets and trims FRP/steel members to precise reserved lengths. Pneumatic cylinder actuators provide quick, repeatable motion and minimize downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors deliver precise positioning and feedback control. Inline checks feed control charts so operators can adjust drifts before out-of-control conditions occur.
| Feature | Capability | Result |
|---|---|---|
| CLX-BPO2 | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Drive | 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 loading 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 brings industrial-grade stripping and trimming to our line, reducing cycle time while keeping prep consistent.
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 and photoelectric control deliver exact detection and repeatable actuation. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Line Speed
Typical operation speed is 1.5s per cycle. This converts to steady throughput under continuous line 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 strength member 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 available for non-standard cross-sections to maintain precision.
- Auto-eject scrap and sensor start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg weight simplify cell integration.
- Cylinder-driven motion and closed-loop control boost reliability and lower maintenance interruptions.
| Spec | Value | Benefit |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0–11.0 mm | Meets strength and termination needs |
| Power/Size | 110–220V, 50W; 40×18×18 cm | Easy integration into existing equipment |
Using this machine, Shanghai Weiye OFC Equipment standardizes prep so field teams get drop parts install-ready. The CLX-BPO2 helps our production lines meet volume goals without compromising quality.
Custom Specs for 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 get install-ready reels.
Choose 1–4 core designs with single-mode or multimode fiber. Options include OS1/OS2 plus OM2–OM4 plus G.652D/G.657 variants to match your optics and connector plans.
We match sheath colors to Pantone codes for fast field ID and consistent asset tagging.
Jackets, Legends & Branding
Select LSZH, PVC, or 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 1/2/4 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 | Typical | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Less staging, easier reels |
| Jacket | LSZH / PE / PVC | Indoor/Outdoor fit |
| Design | Bow-type / Self-supporting | Routing and span flexibility |
As a supplier, Shanghai Weiye schedules runs to your plan and provides docs that detail final specs for straightforward QA on site.
Quality assurance, testing, and documentation
Shanghai Weiye OFC Equipment builds checkpoints into production so every item has recorded acceptance data at ship.
High-temperature, salt spray, and vibration laboratory testing
Our lab conducts elevated-temperature exposure, salt spray corrosion, and vibration tests 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 inspection gates prevent nonconforming shipments before they leave the factory.
Traceability and compliance
Batch records link tests to reels/serials so audits and warranty claims are simple 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.
- Quality packages include spec confirmation and formatted test data for quick review.
- Ongoing trend analysis drive preventive maintenance and raise long-term reliability.
| Test | Why | Outcome |
|---|---|---|
| Heat exposure | Material stability | Validated heat endurance |
| Salt-fog | Corrosion robustness | Outdoor suitability |
| Vibration | Mechanical robustness | Reduced field failures |
Pricing and cost drivers for FTTH drop cable
Budgeting for a drop run starts with fiber and jacket choices and is refined by volume and customization.
Typical prices vary widely—from about $30 to $1,000 per unit—based on fiber grade, jacket material, length, and design structure.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, jacket material, and the chosen structure for deployment.
Self-supporting designs and steel strength elements raise material and labor input. Custom sheath colors/logos/legends add setup and influence price for short runs.
How Volume & Options Affect Cost
Longer reels and higher volume orders reduce unit cost. Small quantities often include setup charges and higher per-unit charges.
- Line changeovers and custom tooling increase lead time and add cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Driver | Price impact | Recommendation |
|---|---|---|
| Fiber grade | High impact | Balance spec vs. budget |
| Sheath material | Medium | Compare LSZH vs. PE for total cost |
| Order length / volume | High impact | Consolidate runs to cut unit cost |
Lead times, MOQ, and delivery for the United States
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align staffing and sites. Predictable schedules cut downtime and control costs when a rollout is underway.
Typical production windows and capacity planning
Typical production windows are 4–5 days for < 100 km and 7–10 days for orders under 500 km. We schedule line capacity to track your milestones and to keep deliveries on time.
The service team provides updates/tracking so installation teams know when reels arrive. For compressed schedules, we hold contingency capacity to accelerate critical-path orders.
Why MOQ Matters
The MOQ is 1 km. This reflects line setup such as wire and jacket die adjustments that consume start-up material and scrap.
We review your put-ups and staging 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 dictate whether a self-supporting span, 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 correct strength members to control sag and tension for long-term reliability.
Duct installations perform best with low-friction sheaths and crush-resistant constructs so pulling does not damage fibers. PE jackets are typical for underground and buried paths where moisture resistance matters.
Direct-buried designs need correct burial depth 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 prefer LSZH to meet smoke/flame codes. Flat drop profiles strip clean and present controlled stubs for fast ONT terminations.
We guide the choice of steel or FRP (dielectric) strength members based on bonding requirements, lightning exposure, and hardware compatibility. Standardized prep from the production line shortens install time and minimizes scrap.
| Scenario | Key design | Installer note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct burial | PE jacket, moisture barrier | Follow local depth and warning tape rules |
| 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 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 provides engineering support from early requirements through approved drawings and pre-production builds. We provide doc templates and clear installation notes so field crews work from the same plan.
After-sales service covers rapid response, root-cause analysis, and corrective actions. All products ship with full test reports and traceability to help 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.
- Configuration control so shipped items match agreed specs consistently.
| Support area | What we do | Benefit |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| QA/Testing | Lab trials & 100% test reports | Full traceability |
| Service | Rapid replacement & root-cause | Minimized downtime |
Final Thoughts
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
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-enabled prep machines, reduces variability and speeds turnaround. Our equipment and machines standardize strip and stub lengths so installers see consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance design and cost to maximize service life. Dedicated customer support covers scheduling/logistics/after-sales so your deployment remains on plan.
Get in touch with 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.