FTTH Cable Production: Step-by-Step Manufacturing Process
Did you know: more than seventy percent of new broadband deployments in the U.S. now use fiber networks that require precise manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment manages full-cycle fiber secondary coating line manufacturing, from selecting brand fibers like Fujikura® or Corning® SMF-28e to final test reports that deliver 100% QA.
Our FTTH drop designs suit aerial, ducted, and direct-buried installation, with LSZH, polyvinyl chloride (PVC), and polyethylene (PE) jacket options and core counts from 1–4 cores. We supply single-mode OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone 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 < 100 km and seven to ten days under 500 km, with an min. order of 1 km and free-replacement warranty for quality problems.
Read on to learn how materials, testing, and support work together to reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment delivers complete production and laboratory testing for U.S. deployments.
- A range of jacket options and optical grades support indoor/outdoor environments.
- Automated production lines deliver consistent quality and reliable optical performance.
- Fast lead times, low minimums, and brand fiber options help plan procurement reliably.
- Complete reports and after-sales warranty back product reliability and compliance documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment provides customized drop cables with complete test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment combines specialized equipment with tight 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 performs high-temperature, salt spray, and vibration tests to verify durability. Jacket options include LSZH, PVC, and PE. Designs cover bow-type flat and self-supporting styles and use 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 matches operator specs.
How We Produce FTTH Cable
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 secondary coating line 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 available to satisfy sourcing standards.
Strength member integration
Strength members employ dielectric FRP or galvanized steel wire. FRP is ideal where non-conductive runs are required. Steel wire provides tensile strength for long-span aerial runs and grounding needs.
Jacket extrusion and process control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility, and PE for UV/moisture resistance outdoors. Tight process control of extruder temperature and capstan speed keeps line speed stable and dimensional tolerances.
| Member | FRP | Metallic Steel |
|---|---|---|
| Use case | Non-conductive runs | High-tension aerial runs |
| Advantage | Light, non-corrosive | High strength |
| Installer note | Simple terminations | Bonding/grounding required |
Testing & Verification
Inline geometry and concentricity checks run during manufacturing. Final optical tests verify attenuation and reflectance. Each order includes a full test report and lab results from high heat, salt-spray, and vibration trials 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. Material lot records and first-article approvals support traceability and compliance for U.S. projects.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment offers a focused portfolio of drop designs that cover tight indoor routes and exposed aerial spans. Each option pairs tested materials with geometry tuned for field termination and consistent optical performance.
The flat bow-type drop keeps a small footprint for risers and conduit. It keeps bend loss low for simple routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs include a support messenger to handle tension. Choose FRP (dielectric) for non-conductive runs or steel messenger when bonding/grounding and extra tensile strength are required.
Strength member and core layouts
We provide both dielectric and metallic strength member configurations to match safety and EMI rules. Central loose-tube and flat unitube types balance crush resistance and compact fiber unit for quick termination.
Jackets for Indoor/Outdoor
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/optical performance before shipment.
| Type | Best use | Strength element | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | Dielectric FRP | LSZH |
| Self-supporting (aerial) | Aerial spans | Steel wire or FRP | Polyethylene |
| Center loose tube | Higher fiber counts | FRP | LSZH/PE |
| Unitube flat | Low-count, easy strip | FRP/Steel | LSZH or PE |
Production line equipment that ensures quality and speed
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment reduce 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 reduce operator variability.
The CLX-BPO2 auto-stripping machine uses PLC + photoelectric control. One cycle is about 1.5 seconds, giving real-world speeds near 20 terminal operations per minute.
Automated Cut/Strip for Drop Cords
The equipment strips LSZH and PVC jackets and trims FRP or steel strength members to precise reserved lengths. Cylinder-driven actuators deliver fast, repeatable motion and low downtime.
PLC/photoelectric control for precision and repeatability
PLC logic and photoelectric sensors give exact positioning and closed-loop control. Inline checks feed control charts so operators can adjust drifts before defects grow.
| Feature | Spec | Result |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Materials | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic loading maintain clean workcells.
- Process control plans document calibration and key parameters.
- Integrated assets and trained operators help meet FTTH volume goals without sacrificing accuracy.
What the CLX-BPO2 Adds
The CLX-BPO2 provides industrial-grade strip/trim to our line, reducing cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output and standardize prep quality. The unit cycles in ~1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC/photoelectric control deliver exact detection and repeatable actuation. That control keeps strip and stub lengths within tight tolerances.
Cycle time and throughput
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 strength member stubs are set between 7.0 and 11.0 mm to fit common termination hardware.
Cutting FRP/Steel Members
The machine cleanly cuts FRP and steel wire strength elements while protecting adjacent fibers. Custom tooling are available for nonstandard sizes to preserve precision.
- Automatic waste ejection and sensor-triggered start cut idle time.
- Compact size (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass ease integration into workcells.
- Pneumatic cylinders and closed-loop control improve line reliability and reduce maintenance downtime.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0 to 11.0 mm | Supports termination strength |
| Power/Size | 50W @ 110–220V; 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 supports our lines in meeting volume targets without sacrificing quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures each build to fit your network requirements and simplify field rollout. We combine focused options with predictable schedules so your teams get install-ready reels.
Choose 1 to 4 cores with SM or MM fiber. Options include OS1/OS2 plus OM2–OM4 plus 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 tags.
Branding and Print Options
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom print legends and logos aid inventory/warranty tracking.
Lengths, Packaging & Special Builds
Standard reel lengths are 1/2/4 km with tailored reels and packaging to fit storage/handling. Choose bow-type flat or self-supporting designs and steel wire or FRP strength members to meet span and isolation needs.
| Choice | Common choice | Benefit |
|---|---|---|
| Reel length | 1, 2, or 4 km | Less staging, easier reels |
| Jacket | LSZH, PE, PVC | Indoor/Outdoor fit |
| Structure | Flat bow / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and provides docs 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.
Environmental and Mechanical Tests
Our lab conducts high-temperature exposure, salt fog corrosion, and vibration tests to qualify materials/assemblies. These tests recreate 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 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 accelerate approvals and receiving inspection.
- In-line checks plus final inspection reduce field failures and lower warranty events.
- Quality packages include specifications confirmation and formatted test data for rapid review.
- Continuous test trends inform preventive maintenance and improve long-term reliability.
| Test | Why | Outcome |
|---|---|---|
| High-temperature | Thermal stability | Validated heat endurance |
| Salt-fog | Corrosion resistance | Outdoor suitability |
| Vibration | Resistance to vibration | Reduced field failures |
FTTH Drop Cable Pricing & Cost Drivers
Budgeting for a drop run 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.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, jacket material, and the structural type chosen for deployment.
Self-supporting designs and steel members increase material/labor. Custom colors, logos, and print legends add setup and impact pricing on small runs.
Length/Volume/Customization Impact
Longer reels and higher volume orders lower unit cost. Small quantities often carry setup fees and higher unit prices.
- Line changeovers and custom tooling extend lead time and add to cost.
- Clear RFQs with schedule alignment let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Factor | Effect on price | Guidance |
|---|---|---|
| Fiber grade | High impact | Right-size spec to budget |
| Sheath material | Medium impact | Evaluate LSZH vs PE |
| Length/Volume | Large | Consolidate where possible |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews and sites. Predictable windows cut downtime and help control cost 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 schedule line 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 hold contingency capacity to accelerate critical-path orders.
Why MOQ Matters
The MOQ is one kilometer. This reflects setup needs such as wire and jacket die adjustments that use startup material and generate scrap.
We review your length and staging plans to select reels to reduce waste/handling. Staggered batches can balance inventory with more frequent small-site deliveries.
Installation Scenarios & Readiness
On-site conditions dictate whether a self-supporting span, duct pull, or direct burial is the best fit for a project.
Aerial vs Duct vs Direct-Buried
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with appropriate members to control sag and tension for long-term reliability.
Duct installations work best with low-friction sheaths and crush-resistant builds so pulling avoids fiber damage. 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-resistant jackets to protect the fiber core long-term.
Indoor Distribution and ONT
Indoor riser/plenum routes prefer LSZH to meet smoke/flame codes. Flat drop cable forms strip cleanly and present controlled strength stubs for quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware compatibility. Standardized line prep shortens install time and reduces scrap.
| Scenario | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct burial | PE with moisture barrier | Follow local depth and warning tape rules |
| Interior | LSZH with tight-bend support | Maintain bend radius at wall penetrations |
Our approach delivers a consistent installation across indoor outdoor transitions. That reduces callbacks, speeds activations, and reliable 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 offers 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.
- 24/7 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.
- Configuration control so shipped items match agreed specs consistently.
| Area | What we do | Outcome |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Fewer field issues |
| Testing | Lab trials & 100% test reports | Traceable quality |
| After-sales | Rapid replacement & root-cause | Lower downtime |
Wrap-Up
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
We provide custom FTTH drops 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 robust production line, including CLX-BPO2-enabled prep machines, reduces variability and shortens turnaround. Our equipment and machines standardize strip/stub lengths so installers get consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance design and cost to extend service life. Dedicated customer support covers scheduling/logistics/after-sales so your deployment remains on plan.
Contact Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every shipment with lab validation and responsive service.
