FTTH Cable Production: How the Manufacturing Process Works
Quick fact: over seventy percent of new broadband deployments in the U.S. now use fiber networks that need high-precision manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment runs complete 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 fit overhead, ducted, and direct burial installation, with LSZH, polyvinyl chloride (PVC), and polyethylene (PE) jacket options and core counts from 1 to 4 cores. We supply OS1/OS2 and OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automated machines and precision equipment stabilize line speed and repeatability high. Typical lead times run four to five days for orders < 100 km and seven to ten days for < 500 km, with an MOQ of 1 km and warranty covering free replacement for confirmed quality issues.
Read on to understand how materials plus testing and support combine to lower lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment delivers full manufacturing with lab validation for United States projects.
- Multiple jacket choices and optical grades fit varied installation environments.
- Automated production lines provide stable quality and reliable optical performance.
- Fast lead times, low MOQ, and recognized brand fibers support reliable procurement planning.
- Complete reports and after-sales warranty support product reliability and documentation needs.
FTTH Manufacturing Expertise 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 specialized maker and supplier, Shanghai Weiye OFC Equipment pairs purpose-built equipment with stringent material control. We provide custom builds and services for single-family and MDU rollouts. Every order comes with full QA coverage and complete test reports.
Our lab runs high-temperature, salt-fog, and vibration tests to verify durability. Jacket options cover LSZH, PVC, and PE. Designs cover flat bow-type and figure-8/self-supporting styles and support brand fibers such as Fujikura® and Corning® SMF-28e.
- Controlled production lines and in-process checks for auditable shipments.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixturing and calibration reduce variability so every cable meets operator standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with rigorous test routines.
Fiber Selection & Brand Options
We select fiber secondary coating line to bend radius, loss, and deployment type. Options include OS1/OS2 and OM2–OM4 and ITU-T G.652D, G.657.A1/A2. Brand fibers such as Fujikura and Corning SMF-28e are available to satisfy sourcing standards.
Integrating Strength Members
Strength members use 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 flame/smoke safety, PVC for flexibility and ease of handling, and PE for UV/moisture resistance outdoors. Closed-loop control of extruder temperature and capstan speed keeps line speed stable and dimensional tolerances.
| Member | FRP | Steel wire |
|---|---|---|
| Use case | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Lightweight, inert | Very high tensile strength |
| Installation note | Simple terminations | Bonding/grounding required |
In-Process and Final Testing
Inline geometry/concentricity checks operate in-line. Final optical tests verify loss and return loss. Each order ships with a 100% 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 under 100 km in 4–5 days and under 500 km in 7–10 days. Lot records and FAI approvals provide traceability and compliance for U.S. programs.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment provides a focused portfolio of drop designs that fit indoor risers and long aerial runs. Each option combines tested materials with field-termination geometry and stable optical performance.
The bow-type flat drop cable minimizes 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 messenger element to carry tensile loads. Choose FRP (dielectric) for electrical isolation or steel messenger when bonding/grounding and higher tensile strength are required.
Strength member and core layouts
We offer both dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and unitube flat types balance crush resistance and fiber ribbone line for quick termination.
Indoor vs 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.
| Type | Application | Strength element | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | Dielectric FRP | LSZH |
| Self-supporting | Aerial spans | Steel wire or FRP | Polyethylene |
| Center loose tube | Higher fiber counts | FRP | LSZH or PE |
| Flat unitube | Low count, quick strip | FRP or steel | LSZH/PE |
Production Assets for Speed and Quality
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for patch cord prep.
Our production line uses automated machines that cut/strip drop cords to raise throughput and reduce operator variability.
The CLX-BPO2 automated stripper runs under PLC and photoelectric control. One cycle is about 1.5 seconds, giving ~20 terminals per minute in production.
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. Pneumatic cylinder actuators deliver fast, repeatable motion and minimize downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors deliver precise positioning and closed-loop control. Inline checks update SPC charts so operators can correct trends before defects grow.
| Feature | Spec | Result |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Drive | Pneumatic cylinders | High speed and reliability |
| Materials | 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.
- Process control plans capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets without compromising accuracy.
CLX-BPO2 auto-stripping machine capabilities in our line
The CLX-BPO2 provides industrial-grade strip/trim to our line, reducing cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment deploys the CLX-BPO2 to increase throughput 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 enable precise 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.
Jacket Strip & Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable 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.
FRP & Steel Member Handling
The machine cuts FRP/steel strength elements cleanly while protecting adjacent fibers. Customized cutters are available for non-standard cross-sections to maintain precision.
- Automatic waste ejection 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 PLC/photoelectric control improve line reliability and reduce maintenance downtime.
| Spec | Value | Benefit |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | Supports high-volume runs |
| Strip lengths (A) | 17.5–35.0 mm | Fits common connector processes |
| Stub (B) | 7.0–11.0 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 receive drop parts ready for quick installation. 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 every order to meet 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, and OM2–OM4 plus G.652D/G.657 variants to match your optics and connector plans.
We Pantone-match sheath colors for quick field identification and consistent asset tags.
Jacket materials, print legends, and branding
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom legends/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 bow-type flat or self-supporting designs and steel wire or FRP strength members to fit span and isolation requirements.
| Option | Typical | Advantage |
|---|---|---|
| Length | 1 / 2 / 4 km | Simpler staging and reels |
| Jacket | LSZH, PE, PVC | Indoor/Outdoor fit |
| Structure | Bow-type / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and delivers documentation that lists final specifications for straightforward QA on site.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment builds checkpoints into production so every item ships with recorded acceptance data.
Environmental and Mechanical Tests
Our lab conducts high-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials and assemblies. These tests recreate field stresses for indoor/outdoor applications.
100% test reports for every cable
Every fiber optic cable includes a 100% test report that records loss, return loss, and key geometry where applicable. Final QC gates stop nonconforming items before they leave the factory.
Audit Trail and Compliance
Lot/batch records link tests to reels/serials so audits and claims are easy to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- Line checks and final inspection prevent field failures and cut warranty events.
- QA packages include spec confirmation and formatted data for rapid review.
- Ongoing trend analysis drive preventive maintenance and raise long-term reliability.
| Test | Why | Result |
|---|---|---|
| Heat exposure | Material stability | Pass at target temperature |
| Salt-fog | Corrosion robustness | Qualified for outdoor use |
| Mechanical vibration | Mechanical robustness | Reduced field failures |
FTTH Drop Cable Pricing & Cost Drivers
Budgeting for a drop run 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 grade, jacket material, and the chosen structure for deployment.
Self-supporting designs and steel members increase material/labor. Custom sheath colors/logos/legends add setup time and impact pricing on small runs.
Length/Volume/Customization Impact
Longer put-ups and larger volumes lower unit cost. Short runs often include setup charges and higher unit prices.
- Line changeovers and custom tooling extend lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Driver | Effect on price | Guidance |
|---|---|---|
| Fiber grade | Large | Right-size spec to budget |
| Sheath material | Medium impact | Compare LSZH vs. PE for total cost |
| 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 help control cost when a rollout is underway.
Production Windows & Capacity
Typical production windows are 4–5 days for < 100 km and 7–10 days for < 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 can plan arrivals. For compressed schedules, we hold contingency capacity to pull in critical-path orders.
Why MOQ Matters
The MOQ is 1 km. This reflects setup needs such as wire and jacket 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 with more frequent small-site deliveries.
Where and How to Deploy
Site conditions dictate 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 correct strength members to control sag and tension for long-term stability.
Duct installations perform best with low-friction jackets and crush-resistant builds so pulling does not damage fibers. 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/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 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 feature | Field note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Underground duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow depth/warning tape codes |
| Interior | 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 pilot builds. We deliver documentation 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 includes free replacement for confirmed quality issues.
- Schedule coordination for expedites and urgent changes.
- Configuration control so shipped items match agreed requirements every time.
| Support area | Scope | Benefit |
|---|---|---|
| Engineering | Spec review & pre-production builds | Fewer field issues |
| Testing | Lab + 100% reports | Full traceability |
| Service | Fast replace + RCA | Lower downtime |
Final Thoughts
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
We deliver customized FTTH drop solutions that pair material choices with validated manufacturing and lab testing. Every reel ships with a 100% test report and documented lab trials to support U.S. field acceptance.
A robust production line, including CLX-BPO2 prep assets, cuts variability and speeds turnaround. Our equipment and machines standardize strip and stub lengths so installers get consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance performance and cost to extend service life. Dedicated customer support covers scheduling/logistics/after-sales so your deployment stays 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.
