FTTH Cable Production: Manufacturing Process Explained
Surprising fact: in excess of seventy percent of new broadband deployments in the U.S. now rely on fiber networks that require high-precision manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment manages complete compact fiber unit manufacturing, from sourcing brand fibers like Fujikura or Corning SMF-28e to complete test reports that guarantee full quality assurance.
Our FTTH drop designs are built for aerial, underground, and direct-buried installation, with LSZH, polyvinyl chloride (PVC), and polyethylene (PE) jacket options and configurations from 1–4 cores. We offer single-mode OS1/OS2 and OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone sheath colors, and logo printing.
Automation and high-precision equipment stabilize line speed and maximize repeatability. Typical lead times run four to five days for orders under 100 km and 7–10 days under 500 km, with an min. order of 1 km and free-replacement warranty for quality problems.
Keep reading to understand how our materials, tests, and support combine to lower lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment provides full manufacturing with lab validation for U.S. deployments.
- Multiple jacket choices and optical grades cover indoor/outdoor environments.
- Automated production lines deliver consistent quality and stable optical performance.
- Quick lead times, low minimums, and recognized brand fibers support reliable procurement planning.
- Comprehensive test reports and after-sales warranty back product reliability and documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment delivers tailored drop solutions with complete test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment pairs specialized equipment with tight material control. We offer custom builds and services for single-family and MDU rollouts. Every order includes full QA coverage and complete test reports.
Our lab runs high heat, salt-fog, and vibration tests to validate durability. Jacket options include LSZH, PVC, and PE. Designs cover bow-type flat and self-supporting styles and support brand fibers such as Fujikura and Corning® SMF-28e.
- Controlled production lines and in-process checks for fully auditable shipments.
- Technical support for specs, trials, and ramp to volume.
- Modern fixtures and calibration reduce variability so every cable matches operator specs.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, pairing brand fiber choices with disciplined test flows.
Optical fiber selection and brand options
We select fiber ribbon line to bend radius, loss, and install environment. 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.
Integrating Strength Members
Strength members use 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.
Extrusion & 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 critical dimensions.
| Member | Dielectric FRP | Steel wire |
|---|---|---|
| Primary use | Non-conductive runs | Aerial spans, high tensile |
| Advantage | Lightweight, inert | Very high tensile strength |
| Installation note | Simple terminations | Requires grounding |
Inline and final testing
Inline geometry and concentricity checks run during manufacturing. Final optical tests confirm loss and return loss. Each order includes a full test report and lab results from high-temperature, salt-spray, and vibration tests to confirm handling for drop terminations and field use.
Typical lead times are 4–5 days for < 100 km and under 500 km in 7–10 days. Lot records and first-article approvals support traceability and compliance for U.S. programs.
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 pairs tested materials with geometry tuned for field termination and stable optical performance.
The flat bow-type drop minimizes footprint for risers/ducts. It keeps bend loss low for simple routing in hallways and MDUs.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs use a support messenger to handle tension. Choose dielectric FRP for non-conductive runs or steel messenger when bonding and extra tensile strength are required.
Strength member and core layouts
We offer both dielectric and metallic strength member configurations to match safety and EMI rules. Center loose tube and flat unitube types balance crush resistance and fiber secondary coating line for fast terminations.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each family is qualified for mechanical/optical performance before shipment.
| Type | Application | Strength member | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | FRP (dielectric) | LSZH |
| Self-supporting (aerial) | 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/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 patch cord prep.
Our production line integrates automated machines that cut/strip drop cords to increase output 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 deliver fast, repeatable motion and minimize downtime.
PLC/photoelectric control for precision and repeatability
PLC logic and photoelectric sensors deliver precise positioning and feedback control. Inline checks update SPC charts so operators can correct trends before out-of-control conditions occur.
| Item | Spec | Benefit |
|---|---|---|
| CLX-BPO2 | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Material handling | LSZH/PVC; FRP/steel | Clean, accurate preps |
| Process control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic feeders keep the line clean.
- PCPs document calibration and key parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets without sacrificing accuracy.
CLX-BPO2 Capabilities on Our Line
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 terminal 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 keeps strip and stub lengths within tight tolerances.
Line Speed
Typical operation speed is 1.5s per cycle. This converts to steady throughput under normal production conditions.
Jacket Strip & Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable strip length from 17.5 to 35.0 mm. Reserved strength member stubs are adjustable from 7.0–11.0 mm to fit common termination hardware.
FRP & Steel Member Handling
The machine cleanly cuts FRP and steel wire strength elements while protecting adjacent fibers. Custom tooling are offered for nonstandard sizes to maintain precision.
- Automatic waste ejection and sensor start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight ease integration into workcells.
- Cylinder-driven motion and closed-loop control improve line reliability and lower maintenance interruptions.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5–35.0 mm | Compatible with common connectors |
| Reserved stub (B) | 7.0 to 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 prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 helps our production lines meet volume goals without compromising quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures every order 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, and OM2–OM4 plus 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.
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 km, 2 km, and 4 km with tailored reels and packaging to fit storage/handling. Choose flat bow-type or self-supporting and steel wire or FRP strength members to fit span and isolation requirements.
| Choice | Common choice | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Less staging, easier reels |
| Sheath | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Design | Bow-type / Self-supporting | Flexible routing/span |
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 builds checkpoints into production so every item has recorded acceptance data at ship.
Environmental and Mechanical Tests
Our lab conducts high-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials/assemblies. These tests simulate field stresses for indoor and outdoor use.
Per-Reel 100% Reports
Every fiber optic cable includes a 100% test report that logs attenuation, return loss, and geometry where applicable. Final QC gates stop nonconforming items before they leave the factory.
Audit Trail and Compliance
Lot/batch records tie test data to reels and serials so audits and claims are easy to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection prevent field failures and lower warranty events.
- QA packages include spec confirmation and formatted test data for quick review.
- Continuous test trends drive preventive maintenance and raise long-term reliability.
| Trial | Why | Result |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion robustness | Qualified for outdoor use |
| Mechanical vibration | Resistance to vibration | Improved field reliability |
Pricing and cost drivers for FTTH drop cable
Budgeting for a drop run begins with fiber/jacket selection 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), reel length, and structural design.
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 sheath colors/logos/legends add setup time and influence price for short runs.
How Volume & Options Affect Cost
Longer put-ups and larger volumes reduce unit cost. Small quantities often include setup charges and higher unit prices.
- Line changeovers and custom tooling extend lead time and add 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.
| Factor | Effect on price | Guidance |
|---|---|---|
| Optical grade | High impact | Right-size spec to budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Order length / volume | Large | Consolidate where possible |
Logistics for the U.S.
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 maintain on-time delivery.
The service team issues production updates and tracking so installation teams know when reels arrive. For compressed schedules, we hold contingency capacity to accelerate critical-path orders.
Minimum order quantity and why it matters
The MOQ is one kilometer. This reflects setup needs such as wire and jacket die adjustments that consume start-up material and scrap.
We review your put-ups and staging to select reels to reduce waste/handling. Staggered batches can balance inventory holding with more frequent small-site deliveries.
Installation readiness and application scenarios
On-site conditions determine whether a self-supporting span, duct pull, or direct-buried run is the best fit for a project.
Deployment Considerations
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with appropriate members to manage sag/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 common 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 stubs for quick ONT termination.
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.
| Scenario | Key design | Field note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Underground duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct burial | PE with moisture barrier | Follow depth/warning tape codes |
| Indoor | LSZH with 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 testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment provides 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 includes fast response, RCA, and corrective action. All products ship with full test 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 urgent changes or acceleration requests.
- Configuration control so shipped items match agreed specs consistently.
| Support area | What we do | Outcome |
|---|---|---|
| Engineering | Spec review & pre-production builds | Reduced field issues |
| QA/Testing | Lab + 100% reports | Full traceability |
| After-sales | Rapid replacement & root-cause | Lower 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 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 prep assets, cuts variability and speeds turnaround. Our equipment set standardize strip/stub lengths so installers see consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance design and cost to extend service life. Dedicated support covers scheduling/logistics/after-sales so your deployment remains 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 lab validation and responsive support.