FTTH Cable Production: Manufacturing Process Explained
Surprising fact: in excess of 70% of U.S. broadband rollouts now rely on fiber networks that require tight manufacturing control to hit performance targets.
Shanghai Weiye OFC Equipment runs complete fiber secondary coating line manufacturing, from sourcing brand fibers like Fujikura® or Corning SMF-28e to final test reports that deliver 100% QA.
Our drop cable designs are built for overhead, ducted, and direct burial installation, with LSZH, PVC, and PE jacket options and core counts from 1 to 4 cores. We supply single-mode OS1/OS2 and OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone sheath colors, and custom logo printing.
Automated machines and high-precision equipment keep line speed steady and maximize repeatability. Typical lead times are four to five days for orders under 100 km and 7–10 days for < 500 km, with an MOQ of 1 km and warranty covering free replacement for confirmed quality issues.
Continue to learn how our materials, tests, and support help reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment offers full manufacturing with lab validation for United States projects.
- A range of jacket options and optical grades support different install environments.
- Automated lines and machines ensure consistent quality and stable optical performance.
- Fast lead times, low minimums, and recognized brand fibers support reliable procurement planning.
- Comprehensive test reports and warranty back product reliability and documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment provides tailored drop solutions with full test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment combines specialized equipment with tight material control. We offer custom builds and services for residential and MDU rollouts. Every order includes 100% quality assurance and full test reports.
Our lab conducts high heat, salt-fog, and vibration tests 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.
- Controlled production lines and in-process checks for shipments with audit trails.
- Technical support for requirements, pilots, and scaling.
- Modern fixtures and calibration minimize variation so every cable meets carrier standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with disciplined test flows.
Fiber Selection & 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.
Strength Member Options
Strength members use dielectric FRP or galvanized steel wire. FRP is preferred where non-conductivity is necessary. Steel wire provides tensile strength for longer aerial spans and grounding needs.
Jacket extrusion and process control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility, and PE for outdoor UV and moisture resistance. Tight process control of temperature and capstan ratios keeps line speed stable and dimensional tolerances.
| Component | Dielectric FRP | Metallic Steel |
|---|---|---|
| Use case | Electrical isolation | Aerial spans, high tensile |
| Advantage | Light, non-corrosive | High strength |
| Installer note | Easier terminations | Requires grounding |
Inline and final testing
Inline geometry/concentricity checks operate in-line. Final optical tests verify loss and reflectance. 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 under 500 km in 7–10 days. Material lot records and first-article approvals support traceability and compliance for U.S. programs.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment provides 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 stable optical performance.
The bow-type flat drop cable keeps a small footprint for risers/ducts. It keeps bend loss low for simple routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
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 higher tensile strength are required.
Layouts & Strength Members
We provide dielectric and metallic strength member configurations to meet safety/EMI requirements. Center loose tube and flat unitube types balance crush resistance and fiber ribbone line for fast terminations.
Jackets for Indoor/Outdoor
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.
| Design | Best use | Strength member | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting (aerial) | Aerial spans | Steel wire or FRP | PE |
| Center loose tube | Higher fiber counts | FRP | LSZH or PE |
| Flat unitube | Low count, quick strip | FRP/Steel | LSZH or PE |
Production Assets for Speed and Quality
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for drop patch preparation.
Our production line uses automated machines that cut and strip drop patch cords to increase output and cut labor variability.
The CLX-BPO2 automated stripper uses PLC + 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/PVC jackets and trims FRP or steel strength members to precise reserved lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and low downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors give exact positioning and closed-loop control. Inline checks update SPC charts so operators can adjust drifts before out-of-control conditions occur.
| Item | Capability | Benefit |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Materials | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Process control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Automated waste ejection and ergonomic loading keep the line clean.
- Process control plans capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without sacrificing accuracy.
CLX-BPO2 Capabilities on 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 deploys the CLX-BPO2 to raise output 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 deliver exact detection and repeatable actuation. That control keeps strip and stub lengths within tight tolerances.
Line Speed
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 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.
Handling FRP and steel wire strength members
The machine cleanly cuts FRP and steel wire strength elements while protecting neighboring fibers. Custom tooling are offered for non-standard cross-sections to maintain precision.
- Automatic waste ejection and sensor start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass simplify cell integration.
- Cylinder-driven motion and closed-loop control improve line reliability and lower maintenance interruptions.
| Specification | Value | Benefit |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5–35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0 to 11.0 mm | Supports termination strength |
| Power & size | 110–220V, 50W; 40×18×18 cm | Simple integration |
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.
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 get install-ready reels.
Choose 1–4 core designs with single-mode or multimode fiber. Options include OS1/OS2 plus OM2–OM4 along with G.652D and 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.
Jackets, Legends & Branding
Select LSZH, PVC, or PE jackets based on route and safety rules. Custom legends/logos support inventory and warranty tracking.
Put-Ups, Packaging, and Structures
Standard put-ups 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 FRP or steel members to fit span and isolation requirements.
| Choice | Common choice | Benefit |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Less staging, easier reels |
| Sheath | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Structure | Bow-type / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye schedules runs to your plan and delivers documentation that lists final specifications for straightforward QA on site.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment builds checkpoints into production so every item has recorded acceptance data at ship.
Environmental and Mechanical Tests
Our lab runs elevated-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials and assemblies. These tests simulate field stresses for indoor and outdoor use.
Full Test Reports for Every Reel
Every fiber optic cable includes 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 and compliance
Batch records link tests to reels/serials so audits and warranty claims are simple to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection prevent field failures and cut warranty events.
- Quality packages include spec confirmation and formatted test data for quick review.
- Ongoing trend analysis drive preventive maintenance and improve long-term reliability.
| Test | Purpose | Result |
|---|---|---|
| Heat exposure | Material stability | Pass at target temperature |
| Salt spray | Corrosion resistance | Outdoor suitability |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
Pricing and cost drivers for FTTH drop cable
Budgeting for a drop run begins with fiber/jacket selection and is refined by volume and customization.
Typical prices range broadly—from about $30–$1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket material, reel length, and structural design.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber grade, jacket material, and the chosen structure for deployment.
Self-supporting structures and steel members increase material/labor. Custom sheath colors/logos/legends add setup and impact pricing on small runs.
Length/Volume/Customization Impact
Longer reels and higher volume orders reduce unit cost. Short runs often include setup charges and higher per-unit charges.
- Changeovers and special cutters increase lead time and add to cost.
- Clear RFQs with schedule alignment let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets over phases.
| Factor | Price impact | Guidance |
|---|---|---|
| Fiber grade | Large | Balance spec vs. budget |
| Jacket type | Medium | Evaluate LSZH vs PE |
| Order length / volume | Large | Consolidate runs to cut unit cost |
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 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 issues production updates and tracking so installation teams can plan arrivals. For tight schedules, we hold contingency capacity to accelerate critical-path orders.
MOQ and Rationale
The MOQ is 1 km. 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 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 span, ducted pull, or direct-buried run is the right choice 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 builds so pulling avoids fiber damage. PE jackets are typical for underground and buried paths where moisture resistance is needed.
Direct-buried designs require proper depth control per local codes and moisture barriers to protect the optic core over time.
Indoor Distribution and ONT
Indoor riser and plenum routes prefer LSZH to meet smoke/flame codes. 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 risk, and hardware compatibility. Standardized line prep shortens install time and reduces scrap.
| Scenario | Key design | Field note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Duct | Low-friction, crush-resistant | Use pull tape and proper lubricant |
| Direct-buried | PE with moisture barrier | Follow depth/warning tape codes |
| Interior | LSZH jacket, tight bend support | Maintain bend radius at penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That reduces callbacks, faster activations, and reliable field performance for your system.
Comprehensive Support & After-Sales
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 pre-production 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 support 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 requirements every time.
| Support area | Scope | Benefit |
|---|---|---|
| Tech/Eng | Specs + pilots | Reduced field issues |
| QA/Testing | Lab + 100% reports | Traceable quality |
| After-sales | Fast replace + RCA | Lower downtime |
Final Thoughts
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 lab trials to support field acceptance in the United States.
A robust production line, including CLX-BPO2 prep assets, 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 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 stays on plan.
Contact Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with lab validation and responsive support.