FTTH Cable Production: How the Manufacturing Process Works
Did you know: over seventy percent of U.S. broadband rollouts now rely on fiber networks that need high-precision manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment handles end-to-end fiber secondary coating line manufacturing, from selecting brand fibers like Fujikura® or Corning SMF-28e to complete test reports that ensure 100% quality assurance.
Our drop cable designs are built for overhead, ducted, and direct burial installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and PE jacket options and configurations from 1 to 4 cores. We supply OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone-matched sheath colors, and logo printing.
Automated machines and precision equipment stabilize line speed and maximize repeatability. Typical lead times are 4–5 days for orders under 100 km and 7–10 days for < 500 km, with an min. order of 1 km and free-replacement warranty for quality problems.
Read on to see how materials, testing, and support help reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment offers full manufacturing with lab validation for U.S. deployments.
- Multiple jacket choices and fiber grades fit varied installation environments.
- Automated production lines provide consistent quality and stable optical performance.
- Quick lead times, low minimums, and recognized brand fibers support reliable procurement planning.
- Complete reports and warranty support product reliability and compliance documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment provides tailored drop solutions with complete test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment pairs purpose-built equipment with stringent 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 runs high heat, salt-fog, and vibration testing to verify 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.
- Documented line control and production checks for shipments with audit trails.
- Engineering support for specification reviews, trials, and volume ramp.
- Modern fixtures and calibration reduce variability so every cable meets carrier standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, combining brand fiber choices with strict test routines.
Fiber Selection & Brand Options
We match FTTH cable production line to minimum bend radius, loss, and install environment. Options include OS1, OS2, OM2–OM4 and ITU-T G.652D, G.657.A1/A2. Brand fibers such as Fujikura and Corning SMF-28e are offered to satisfy sourcing standards.
Strength member integration
Strength members use FRP (dielectric) or galvanized steel wire. FRP is preferred where non-conductivity is necessary. Steel wire adds tensile strength for long-span aerial runs 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. Tight process control of extruder temperature and capstan speed stabilizes line speed and dimensional tolerances.
| Component | Dielectric FRP | Metallic Steel |
|---|---|---|
| Primary use | Electrical isolation | Aerial spans, high tensile |
| Advantage | Lightweight, inert | High strength |
| Installer note | Easier terminations | Bonding/grounding required |
In-Process and Final Testing
Inline geometry and concentricity checks operate in-line. Final optical tests confirm attenuation and reflectance. Each order includes a 100% test report and lab results from high-temperature, salt fog, and vibration tests to confirm handling for drop terminations and field use.
Typical lead times are 4–5 days for < 100 km and 7–10 days for < 500 km. Lot records and FAI approvals support traceability and compliance for U.S. projects.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment offers a focused portfolio of FTTH 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 keeps a small footprint for risers/ducts. It reduces bend loss for easy routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs include a messenger element to carry tensile loads. Choose dielectric FRP for electrical isolation or steel messenger when bonding and extra tensile strength are required.
Layouts & Strength Members
We offer dielectric and metallic strength member configurations to match safety and EMI rules. Central loose-tube and unitube flat types balance crush resistance and fiber secondary coating 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 family is validated for mechanical/optical performance before shipment.
| Type | Application | Strength member | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting | Aerial spans | Steel wire or FRP | PE |
| Central loose-tube | Higher-count builds | Dielectric FRP | LSZH or PE |
| Unitube flat | Low count, quick strip | FRP/Steel | LSZH or PE |
Production line equipment that ensures quality and speed
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for drop patch preparation.
Our production line integrates automated machines that cut/strip drop cords to increase output and cut labor variability.
The CLX-BPO2 auto-stripping machine 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/PVC jackets and trims FRP or steel strength members to precise stub 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 closed-loop control. Inline checks update SPC charts so operators can adjust drifts before out-of-control conditions occur.
| Feature | Spec | Result |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Pneumatic cylinders | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Automated waste ejection and ergonomic loading keep the line clean.
- Process control plans capture calibration intervals and critical parameters.
- Integrated assets and trained operators 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, cutting 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.
Throughput & Cycle Time
Typical operation speed is ~1.5 seconds 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 strip length from 17.5 to 35.0 mm. Reserved stubs are adjustable from 7.0–11.0 mm to match common termination hardware.
FRP & Steel Member Handling
The machine cleanly cuts FRP and steel wire strength elements while protecting neighboring fibers. Custom tooling are offered for nonstandard sizes to maintain precision.
- Auto-eject scrap and sensor start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight simplify cell integration.
- Cylinder-driven motion and PLC/photoelectric control boost reliability and lower maintenance interruptions.
| Spec | Rating | Benefit |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Fits common connector processes |
| Stub (B) | 7.0 to 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 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 to 4 cores with SM or MM fiber. Options include OS1, OS2, and OM2–OM4 along with G.652D and G.657 variants to match your optics and connector plans.
We match sheath colors to Pantone codes for quick field identification and consistent asset tags.
Jacket materials, print legends, and branding
Select LSZH/PVC/PE jackets based on route and safety rules. Custom print legends and logos aid inventory/warranty tracking.
Lengths, Packaging & Special Builds
Standard put-ups 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 FRP or steel members to meet span and isolation needs.
| Option | Common choice | Advantage |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Simpler staging and reels |
| Sheath | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Design | Flat bow / Self-supporting | Routing and span flexibility |
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 runs elevated-temperature exposure, salt fog corrosion, and vibration tests to qualify materials and assemblies. These tests recreate 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.
Audit Trail and Compliance
Batch records tie test data to reels and serials so audits and claims are easy to verify. Documentation uses standard customer templates to accelerate approvals and receiving inspection.
- Line checks and final inspection prevent 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 improve long-term reliability.
| Test | Why | Result |
|---|---|---|
| High-temperature | Material stability | Validated heat endurance |
| Salt spray | Corrosion robustness | Outdoor suitability |
| Vibration | Resistance to vibration | Improved field reliability |
Cost Drivers and Pricing
Budgeting for a drop run starts with fiber and jacket choices 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 chemistry (LSZH, PVC, PE), length, and structural design.
Primary Cost Inputs
The primary cost drivers are fiber grade, jacket material, and the structural type chosen for deployment.
Self-supporting designs and steel strength elements increase material/labor. Custom colors, logos, and print legends add setup time and impact pricing on small runs.
Length/Volume/Customization Impact
Longer put-ups and larger volumes reduce unit cost. Small quantities often carry setup fees and higher unit prices.
- Changeovers and special cutters 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 across phases.
| Factor | Price impact | Recommendation |
|---|---|---|
| Fiber grade | Large | Right-size spec to budget |
| Jacket type | Medium | Compare LSZH vs. PE for total cost |
| Order length / volume | High impact | Consolidate runs to cut unit cost |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align staffing and sites. Predictable schedules cut downtime and help control cost when a rollout is underway.
Production Windows & Capacity
Typical production windows run 4–5 days for orders under 100 km and 7–10 days for < 500 km. We schedule line capacity to track your milestones and to keep deliveries on time.
The service team issues production updates and tracking so installation teams know when reels arrive. For tight schedules, we reserve contingency capacity to pull in critical-path orders.
MOQ and Rationale
The MOQ is one kilometer. This reflects setup needs 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 holding with frequent, smaller deliveries to job sites.
Where and How to Deploy
On-site conditions determine whether a self-supporting span, duct pull, or direct-buried run 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 appropriate members to manage sag/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 matters.
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 advise on steel vs 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 feature | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Underground duct | Low-friction, crush-resistant | Use pull tape and proper lubricant |
| Direct burial | PE with moisture barrier | Follow local depth and warning tape rules |
| 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, faster activations, and stable field performance for your system.
End-to-end support and after-sales 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 provide doc templates and clear install 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 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 | Outcome |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Reduced field issues |
| Testing | Lab trials & 100% test reports | Traceable quality |
| Service | Fast replace + RCA | Lower downtime |
Final Thoughts
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
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-enabled prep machines, cuts variability and shortens turnaround. Our equipment set 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 maximize 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 laboratory validation and responsive service.