FTTH Cable Production: How the Manufacturing Process Works
Did you know: more than seventy percent of new U.S. broadband builds now depend on fiber networks that require high-precision manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment runs end-to-end fiber secondary coating line manufacturing, from selecting brand fibers like Fujikura® or Corning SMF-28e to complete test reports that guarantee full quality assurance.
Our FTTH drop designs suit aerial, ducted, and direct-buried installation, with LSZH, polyvinyl chloride (PVC), and PE jacket options and arrangements 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 custom logo printing.
Automation and precision equipment stabilize line speed and maximize repeatability. Typical lead times run four to five days for orders < 100 km and seven to ten days under 500 km, with an MOQ of 1 km and free-replacement warranty for quality problems.
Read on to see how our materials, tests, and support work together to reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment delivers end-to-end manufacturing and lab testing for U.S. deployments.
- Multiple jacket choices and fiber grades fit different install environments.
- Automated lines and machines ensure consistent quality and stable optical performance.
- Fast lead times, low MOQ, and brand fiber options keep procurement predictable.
- Complete reports and warranty support product reliability and compliance documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment delivers tailored drop solutions with complete test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment combines purpose-built equipment with tight material control. We offer 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-fog, and vibration testing to verify durability. Jacket options include LSZH, PVC, and PE. Designs offer flat bow-type and self-supporting styles and support brand fibers such as Fujikura® and Corning SMF-28e.
- Documented line control and in-process checks for auditable shipments.
- 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 strict test routines.
Optical fiber selection and brand options
We align fiber secondary coating line to bend radius, attenuation, and install environment. 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 meet procurement standards.
Strength member integration
Strength members employ FRP (dielectric) or metallic steel wire. FRP is ideal where non-conductivity is necessary. Steel wire provides tensile strength for long-span aerial runs and bonding/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. Closed-loop control of temperature and capstan ratios stabilizes line speed and dimensional tolerances.
| Member | Dielectric FRP | Steel wire |
|---|---|---|
| Use case | Electrical isolation | High-tension aerial runs |
| Key benefit | Lightweight, inert | High strength |
| Installation note | Simple terminations | Requires grounding |
Testing & Verification
Inline geometry/concentricity checks run during manufacturing. Final optical tests confirm attenuation and return loss. Each order ships with a 100% test report and lab results from high heat, 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. Material lot records and FAI approvals provide traceability and compliance for U.S. programs.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment offers a compact portfolio of FTTH drop designs that fit indoor risers and long aerial runs. Each option pairs tested materials with geometry tuned for field termination and stable optical performance.
The flat bow-type drop keeps a small footprint for risers/ducts. It reduces bend loss for easy routing in hallways and MDUs.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs use a messenger element to handle tension. Choose dielectric FRP for non-conductive runs or steel messenger when bonding and extra tensile strength are required.
Layouts & Strength Members
We offer both dielectric and metallic strength member configurations to meet safety/EMI requirements. Center loose tube and unitube flat 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 durability. Each family is qualified for mechanical/optical performance before shipment.
| Type | Application | Strength member | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | Dielectric FRP | LSZH |
| Self-supporting | Aerial spans | Steel wire or FRP | Polyethylene |
| Center loose tube | Higher-count builds | Dielectric FRP | LSZH/PE |
| Flat unitube | Low-count, easy strip | FRP/Steel | LSZH or PE |
Production line equipment that ensures quality and speed
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and boost throughput for drop patch preparation.
Our production line integrates automated machines that cut and strip drop patch cords to raise throughput and reduce operator variability.
The CLX-BPO2 automated stripper runs under PLC and photoelectric control. One cycle is ~1.5 s, giving real-world speeds near 20 terminal operations per minute.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH and PVC jackets and trims FRP or steel strength members to precise stub lengths. Pneumatic cylinder actuators provide quick, repeatable motion and minimize downtime.
PLC & Photoelectric for Precision
PLC logic + photoelectric sensors deliver precise positioning and closed-loop control. Inline checks update SPC charts so operators can adjust drifts before defects grow.
| Item | Capability | Result |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Drive | Pneumatic cylinders | Fast/reliable motion |
| Material handling | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic loading maintain clean workcells.
- PCPs document calibration and key parameters.
- Integrated assets and trained operators help meet FTTH volume goals 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 increase throughput and standardize prep quality. The unit cycles in ~1.5 seconds, producing around 20 preps per minute in production.
PLC and photoelectric control deliver exact detection and repeatable motion. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Throughput & Cycle Time
Typical operation speed is ~1.5 seconds 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 jacket strip length from 17.5 to 35.0 mm. Reserved stubs are adjustable from 7.0–11.0 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 offered for non-standard cross-sections to maintain precision.
- Automatic waste ejection and sensor-triggered start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass simplify cell integration.
- Cylinder-driven motion and PLC/photoelectric control improve line reliability and reduce maintenance downtime.
| Spec | Rating | Benefit |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5–35.0 mm | Fits common connector processes |
| Stub (B) | 7.0–11.0 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 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 receive ready-to-install products.
Choose 1–4 core designs with SM or MM fiber. Options include OS1/OS2 plus OM2–OM4 along with G.652D and G.657 variants to match your optics and connector plans.
We Pantone-match sheath colors 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 suit storage and handling. Choose bow-type flat or self-supporting designs and FRP or steel members to meet span and isolation needs.
| Option | Typical | Benefit |
|---|---|---|
| Reel length | 1, 2, or 4 km | Less staging, easier reels |
| Jacket | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Structure | 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.
QA, Testing & 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 elevated-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials/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 logs attenuation, return loss, and geometry where applicable. Final QC gates prevent nonconforming shipments 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 follows common customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection reduce field failures and cut warranty events.
- QA packages include spec confirmation and formatted test data for quick review.
- Continuous test trends inform preventive maintenance and raise long-term reliability.
| Test | Purpose | Result |
|---|---|---|
| Heat exposure | Material stability | Validated heat endurance |
| Salt-fog | Corrosion resistance | Qualified for outdoor use |
| Vibration | Resistance to vibration | Reduced field failures |
Pricing and cost drivers for FTTH drop cable
Budget planning for a drop starts with fiber and jacket choices and is shaped by volume and customization.
Typical prices range broadly—from about $30 to $1,000 per unit—based on fiber grade, jacket chemistry (LSZH, PVC, PE), reel length, and design structure.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber grade, jacket material, and the structural type chosen for deployment.
Self-supporting structures and steel members increase material/labor. Custom sheath colors/logos/legends add setup time and impact pricing on small runs.
Order length, volume, and customization impact on price
Longer reels and higher volume orders lower unit cost. Short runs often carry setup fees and higher per-unit charges.
- Line changeovers and custom tooling extend lead time and add cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets across phases.
| Factor | Price impact | Recommendation |
|---|---|---|
| Fiber grade | Large | Balance spec vs. budget |
| Sheath material | Medium impact | Evaluate LSZH vs PE |
| Length/Volume | High impact | 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 are 4–5 days for < 100 km and 7–10 days for < 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 compressed schedules, we hold contingency capacity to accelerate critical-path orders.
MOQ and Rationale
The MOQ is one kilometer. This reflects line setup such as wire/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. Staggered batches can balance inventory with more frequent small-site deliveries.
Installation Scenarios & Readiness
On-site conditions dictate whether a self-supporting span, ducted pull, or direct burial is the best fit for a project.
Aerial, duct, and direct-buried deployment considerations
For aerial runs, Shanghai Weiye OFC Equipment advises self-supporting designs with appropriate 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 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 favor LSZH jackets to meet smoke/flame codes. Flat drop cable forms strip clean and present controlled strength stubs for fast ONT terminations.
We guide the choice of steel or FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware fit. Standardized prep from the production line reduces install time and minimizes scrap.
| Scenario | Key design | Field note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Duct | Low-friction, crush-resistant | Use pull tape and proper lubricant |
| Direct burial | PE with moisture barrier | Follow depth/warning tape codes |
| Interior | LSZH with tight-bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That reduces callbacks, faster activations, and reliable field performance for your system.
Support from Spec to Service
Our team coordinates testing, scheduling, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements capture 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 includes fast response, RCA, and corrective action. All products ship with full reports and traceability to support QA acceptance.
- 24/7 availability for status updates and technical guidance.
- Warranty includes free replacement for confirmed quality issues.
- Schedule coordination for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed specs consistently.
| Support area | What we do | Benefit |
|---|---|---|
| Tech/Eng | Specs + pilots | Fewer field issues |
| Testing | Lab + 100% reports | Traceable quality |
| Service | Fast replace + RCA | Minimized 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 includes a 100% test report and documented trials to support field acceptance in the United States.
A hardened production line, including CLX-BPO2-enabled prep machines, reduces variability and shortens turnaround. Our equipment set standardize strip and 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 support guides scheduling, logistics, and after-sales care 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.
