FTTH Cable Production: Manufacturing Process Explained
Quick fact: more than seventy percent of new broadband deployments in the U.S. now use fiber networks that need tight manufacturing control to meet performance goals.
Shanghai Weiye OFC Equipment handles complete compact fiber unit manufacturing, from selecting brand fibers like Fujikura® or Corning SMF-28e to complete test reports that guarantee full quality assurance.
Our drop designs fit aerial, ducted, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and PE jacket options and core counts from 1 to 4 cores. We supply OS1/OS2 and multimode OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone sheath colors, and custom logo printing.
Automation and high-precision equipment keep line speed steady and repeatability high. Typical lead times are 4–5 days for orders under 100 km and seven to ten days under 500 km, with an MOQ of 1 km and warranty covering free replacement for confirmed quality issues.
Continue to understand how our materials, tests, and support help reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment delivers complete production and laboratory testing for United States projects.
- Multiple jacket choices and optical grades support different install environments.
- Automated production lines provide consistent quality and reliable optical performance.
- Quick lead times, low MOQ, and recognized brand fibers help plan procurement reliably.
- Comprehensive test reports and after-sales warranty back product reliability and documentation needs.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment delivers customized drop cables with complete test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment pairs specialized equipment with tight material control. We provide customized service and products for residential and MDU rollouts. Every order includes full QA coverage and full test reports.
Our lab performs high-temperature, salt-fog, and vibration tests to validate durability. Jacket options include LSZH, PVC, and PE. Designs cover flat bow-type and figure-8/self-supporting styles and use brand fibers such as Fujikura® and Corning SMF-28e.
- Controlled production lines and in-process checks for auditable shipments.
- Technical support for specification reviews, trials, and volume ramp.
- Modern fixtures 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.
Optical fiber selection and brand options
We align fiber draw tower to minimum bend radius, attenuation, 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 offered to meet procurement standards.
Strength Member Options
Strength members use dielectric FRP or galvanized steel wire. FRP is preferred where non-conductivity is necessary. Steel wire adds tensile strength for longer aerial spans and grounding needs.
Extrusion & Process Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility, and PE for UV/moisture resistance outdoors. Closed-loop control of extruder temperature and capstan speed stabilizes line speed and critical dimensions.
| Member | FRP | Metallic Steel |
|---|---|---|
| Use case | Non-conductive runs | Aerial spans, high tensile |
| Advantage | Lightweight, inert | Very high tensile strength |
| Installer note | Simple terminations | Requires grounding |
Testing & Verification
Inline geometry and 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-spray, and vibration trials to qualify field handling and drop terminations.
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.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment offers a focused portfolio of 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 bow-type flat drop cable minimizes footprint for risers and conduit. It keeps bend loss low for simple routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs include a messenger element to handle tension. Choose dielectric FRP for non-conductive runs or steel wire when bonding and higher tensile strength are required.
Core Layouts and Strength Members
We provide dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and unitube flat types balance crush resistance and Fiber coloring machine 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 | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | FRP (dielectric) | LSZH |
| Self-supporting (aerial) | Aerial spans | Steel wire or FRP | Polyethylene |
| Central loose-tube | Higher fiber counts | Dielectric FRP | LSZH or PE |
| Unitube flat | Low-count, easy strip | FRP/Steel | LSZH/PE |
Production Assets for Speed and Quality
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment cut manual handling and boost throughput for drop patch preparation.
Our production line uses automated machines that cut and strip drop patch cords to increase output 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. Cylinder-driven actuators deliver fast, repeatable motion and low downtime.
PLC & Photoelectric for Precision
PLC logic and photoelectric sensors give exact positioning and closed-loop control. Inline checks feed control charts so operators can correct trends before defects grow.
| Feature | Spec | Result |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | High throughput |
| Drive | Pneumatic cylinders | Fast/reliable motion |
| Material handling | LSZH/PVC; FRP/steel | Clean, accurate preps |
| Control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic loading keep the line clean.
- PCPs capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets without compromising accuracy.
What the CLX-BPO2 Adds
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 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/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 1.5s per cycle. This enables steady throughput under continuous line 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 stubs are adjustable from 7.0–11.0 mm to fit common termination hardware.
Cutting FRP/Steel Members
The machine cuts FRP/steel strength elements cleanly while protecting adjacent fibers. Custom tooling are available for nonstandard sizes to preserve precision.
- Automatic waste ejection and sensor-triggered start cut idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass ease integration into workcells.
- Cylinder-driven motion and PLC/photoelectric control improve line reliability and lower maintenance interruptions.
| Spec | Rating | Why it matters |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5–35.0 mm | Compatible with common connectors |
| Reserved stub (B) | 7.0 to 11.0 mm | Supports termination strength |
| Power/Size | 110–220V, 50W; 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 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 receive ready-to-install products.
Choose 1 to 4 cores 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 Pantone-match sheath colors for quick field identification and consistent asset tagging.
Jacket materials, print legends, and branding
Select LSZH/PVC/PE jackets to suit route and safety requirements. 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 custom reels and packaging to suit storage and handling. Choose flat bow-type or self-supporting and steel wire or FRP strength members to fit span and isolation requirements.
| Option | Typical | Advantage |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Simpler staging and reels |
| Jacket | LSZH / PE / PVC | Indoor/Outdoor fit |
| Design | Flat bow / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye schedules runs to your plan and provides docs that detail final specs for straightforward QA on site.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item ships with recorded acceptance data.
High-temperature, salt spray, and vibration laboratory testing
Our lab conducts high-temperature exposure, salt fog corrosion, and vibration tests to qualify materials and assemblies. These tests recreate field stresses for indoor/outdoor applications.
100% test reports for every cable
Every fiber optic cable ships with a 100% test report that records loss, return loss, and key geometry where applicable. Final QC gates prevent nonconforming shipments before they leave the factory.
Traceability & Compliance
Batch records tie test data to reels and serials so audits and warranty claims are simple to verify. Documentation follows common customer templates to accelerate approvals and receiving inspection.
- In-line checks plus final inspection prevent field failures and lower warranty events.
- QA packages include specifications confirmation and formatted test data for quick review.
- Continuous test trends drive preventive maintenance and improve long-term reliability.
| Test | Why | Result |
|---|---|---|
| Heat exposure | Material stability | Pass at target temperature |
| Salt spray | Corrosion robustness | Outdoor suitability |
| Vibration | Mechanical robustness | Reduced field failures |
Cost Drivers and Pricing
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, jacket material, length, and structural design.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber grade, sheath material, and the structural type chosen for deployment.
Self-supporting designs and steel strength elements raise material and labor input. Custom colors, logos, and print legends add setup and influence price for short runs.
Order length, volume, and customization impact on price
Longer reels and higher volume orders reduce unit cost. Small quantities often carry setup fees and higher per-unit charges.
- Line changeovers and custom tooling increase lead time and add cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets over phases.
| Factor | Price impact | Recommendation |
|---|---|---|
| Optical grade | High impact | Right-size spec to budget |
| Jacket type | Medium | Compare LSZH vs. PE for total cost |
| 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 crews and sites. Predictable schedules cut downtime and help control cost when a rollout is underway.
Scheduling & Capacity Planning
Typical production windows are 4–5 days for < 100 km and 7–10 days for < 500 km. We schedule line capacity to match your rollout 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 reserve contingency capacity to accelerate critical-path orders.
Why MOQ Matters
The MOQ is one kilometer. This reflects line setup 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 with frequent, smaller deliveries to job sites.
Installation readiness and application scenarios
On-site conditions determine whether a self-supporting aerial, ducted pull, or direct burial is the right choice for a project.
Aerial, duct, and direct-buried deployment considerations
For aerial runs, Shanghai Weiye OFC Equipment advises self-supporting designs with correct strength members to manage sag/tension for long-term reliability.
Duct installations perform best with low-friction jackets and crush-resistant constructs 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-resistant jackets 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 profiles strip clean 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 fit. Standardized prep from the production line reduces install time and minimizes scrap.
| Scenario | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Duct | Low-friction jacket, crush resistance | Use pull tape + 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 delivers a consistent installation across indoor outdoor transitions. That leads to fewer callbacks, speeds activations, and stable field performance for your system.
End-to-end support and after-sales service
Our team coordinates testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements through approved drawings and pilot 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 support QA acceptance.
- 24/7 availability for status updates and technical guidance.
- Warranty with free replacement if any quality problems are confirmed.
- Schedule coordination for urgent changes or acceleration requests.
- Config control so shipped items match agreed specs consistently.
| Area | Scope | Outcome |
|---|---|---|
| Tech/Eng | Specs + pilots | Fewer field issues |
| QA/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 provide custom FTTH drops that pair material choices with validated manufacturing and lab testing. Every reel includes 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 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 performance and cost to extend service life. Dedicated 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 shipment with laboratory validation and responsive service.