FTTH Cable Production: Step-by-Step Manufacturing Process
Surprising fact: in excess of seventy percent of new U.S. broadband builds now rely on fiber networks that require high-precision manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment manages complete compact fiber unit manufacturing, from choosing brand fibers like Fujikura or Corning SMF-28e to complete test reports that deliver 100% QA.
Our drop cable designs fit aerial, ducted, and direct burial installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and PE jacket options and core counts from 1–4 cores. We provide OS1/OS2 and multimode OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone sheath colors, and logo printing.
Automation and high-precision equipment keep line speed steady and repeatability high. Typical lead times run four to five days for orders < 100 km and 7–10 days for < 500 km, with an min. order of 1 km and warranty for free replacement on quality issues.
Read on to see how our materials, tests, and support help reduce lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment provides full manufacturing with lab validation for United States projects.
- Multiple jacket choices and fiber grades fit varied installation 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 compliance documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment provides tailored drop solutions with full 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/MDU deployments. Every order includes full QA coverage and full test reports.
Our lab performs high heat, salt-fog, and vibration tests to verify durability. Jacket options include 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.
- Documented line control and in-process checks for auditable shipments.
- Technical support for requirements, pilots, and scaling.
- Modern fixtures and calibration reduce variability so every cable matches operator specs.
FTTH cable production
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 match fiber secondary coating line to minimum bend radius, loss, and deployment type. 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 available to meet procurement standards.
Integrating Strength Members
Strength members use dielectric FRP or galvanized steel wire. FRP is ideal where non-conductivity is necessary. Steel wire adds tensile strength for longer aerial spans and grounding needs.
Jacket extrusion and process control
Jacket options include LSZH for indoor flame 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 | Steel wire |
|---|---|---|
| Primary use | Electrical isolation | High-tension aerial runs |
| Advantage | Light, non-corrosive | High strength |
| Installation note | Easier terminations | Requires grounding |
In-Process and Final Testing
Inline geometry and concentricity checks run during manufacturing. Final optical tests confirm attenuation and reflectance. Each order ships with a full test report and lab results from high heat, salt fog, and vibration tests to qualify field handling and drop terminations.
Typical lead times are 4–5 days for < 100 km and under 500 km in 7–10 days. Lot records and first-article approvals provide traceability and compliance for U.S. projects.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment offers a compact 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 easy routing in hallways and MDUs.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs use a messenger element to carry tensile loads. Choose FRP (dielectric) for non-conductive runs or steel wire when bonding and higher tensile strength are required.
Layouts & Strength Members
We offer both dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and flat unitube types balance crush resistance and compact fiber unit for quick termination.
Indoor/outdoor jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor UV and moisture resilience. Each family is qualified for mechanical/optical performance before shipment.
| Type | Best use | Strength element | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting (aerial) | Aerial spans | Steel wire or FRP | Polyethylene |
| Central loose-tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Unitube flat | Low count, quick strip | FRP or steel | LSZH/PE |
Equipment Ensuring Quality and Throughput
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and increase throughput for drop patch preparation.
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 ~1.5 s, giving ~20 terminals per minute in production.
Auto Cut & Strip Capabilities
The equipment strips LSZH and PVC jackets and trims FRP/steel members to precise reserved lengths. Cylinder-driven actuators deliver fast, repeatable motion and low downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors deliver precise positioning and feedback control. Inline checks update SPC charts so operators can adjust drifts before defects grow.
| Item | Spec | Result |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | High throughput |
| Actuation | Pneumatic cylinders | High speed and reliability |
| Materials | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Automated waste ejection and ergonomic feeders maintain clean workcells.
- Process control plans capture calibration intervals and critical parameters.
- Integrated assets and trained operators help meet FTTH volume goals without sacrificing accuracy.
CLX-BPO2 auto-stripping machine capabilities in our line
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, cutting cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output 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 deliver exact detection and repeatable actuation. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Throughput & Cycle Time
Typical operation speed is 1.5s per cycle. This enables steady throughput under continuous line conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable jacket strip length from 17.5 to 35.0 mm. Reserved strength member stubs are set between 7.0 and 11.0 mm to match common termination hardware.
Handling FRP and steel wire strength members
The machine cleanly cuts FRP and steel wire strength elements while protecting adjacent fibers. Custom tooling are offered for nonstandard sizes to maintain precision.
- Auto-eject scrap and sensor start cut idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg weight simplify cell integration.
- Pneumatic cylinders and closed-loop control boost reliability and lower maintenance interruptions.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| 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 get drop parts install-ready. The CLX-BPO2 supports our lines in meeting volume targets without sacrificing quality.
Custom Specs for 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, and OM2–OM4 along with G.652D/G.657 variants to match your optics and connector plans.
We match sheath colors to Pantone codes for fast field ID and consistent asset tagging.
Jacket materials, print legends, and branding
Select LSZH/PVC/PE jackets based on route and safety rules. Custom legends/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 suit storage and handling. Choose bow-type flat or self-supporting designs and steel wire or FRP strength members to meet span and isolation needs.
| Choice | Typical | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Less staging, easier reels |
| Jacket | LSZH / PE / PVC | Indoor/Outdoor fit |
| Structure | Flat bow / Self-supporting | Routing and span flexibility |
As a supplier, Shanghai Weiye aligns runs to your schedule and delivers documentation that lists final specifications for straightforward QA on site.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item has recorded acceptance data at ship.
High-temperature, salt spray, and vibration laboratory testing
Our lab conducts high-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials and assemblies. These tests recreate field stresses for indoor/outdoor applications.
Full Test Reports for Every Reel
Every fiber optic cable ships with a 100% test report that logs attenuation, return loss, and geometry where applicable. Final QC gates stop nonconforming items before they leave the factory.
Audit Trail and Compliance
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.
- Line checks and final inspection prevent field failures and cut warranty events.
- Quality packages include specifications confirmation and formatted test data for quick review.
- Ongoing trend analysis drive preventive maintenance and improve long-term reliability.
| Test | Why | Outcome |
|---|---|---|
| High-temperature | Thermal stability | Validated heat endurance |
| Salt-fog | Corrosion resistance | Outdoor suitability |
| Mechanical vibration | Resistance to vibration | Reduced field failures |
Cost Drivers and Pricing
Budgeting for a drop run begins with fiber/jacket selection and is shaped by volume and customization.
Typical prices vary widely—from about $30 to $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, sheath material, and the chosen structure for deployment.
Self-supporting designs and steel strength elements raise material and labor input. Custom colors, logos, and print legends add setup time and influence price for short runs.
How Volume & Options Affect Cost
Longer reels and higher volume orders lower 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 across phases.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Fiber grade | High impact | Right-size spec to budget |
| Sheath material | Medium impact | Compare LSZH vs. PE for total cost |
| Length/Volume | High impact | Consolidate where possible |
Logistics for the U.S.
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align staffing and sites. Predictable schedules reduce 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 < 500 km. We plan capacity to track your milestones and to keep deliveries on time.
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.
Minimum order quantity and why it matters
The MOQ is 1 km. This reflects line setup such as wire/die adjustments that use startup material and generate scrap.
We review your length and staging plans to select reels to reduce waste/handling. Staggered batches can balance inventory holding with more frequent small-site deliveries.
Installation Scenarios & Readiness
Site conditions dictate 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 recommends self-supporting designs with correct strength members to manage sag/tension for long-term stability.
Duct installations work best with low-friction sheaths and crush-resistant constructs so pulling does not damage fibers. PE jackets are common for underground and buried paths where moisture resistance matters.
Direct-buried designs require proper depth control per local codes and moisture-resistant jackets to protect the fiber core long-term.
Indoor Riser/Plenum & ONT
Indoor riser and plenum routes favor LSZH jackets to meet flame and smoke rules. 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 needs, lightning exposure, and hardware fit. Standardized prep from the production line shortens install time and reduces scrap.
| Deployment | Key design | Installer note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct burial | PE jacket, 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, speeds activations, and reliable field performance for your system.
Comprehensive Support & After-Sales
Our team coordinates tests, line schedules, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements capture through approved drawings and pre-production builds. We provide doc 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 with free replacement if any quality problems are confirmed.
- Coordination of line schedules for expedites and urgent changes.
- Configuration control so shipped items match agreed specs consistently.
| Area | What we do | Outcome |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Reduced field issues |
| QA/Testing | Lab + 100% reports | Full traceability |
| Service | Rapid replacement & root-cause | Lower 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 ships with a 100% test report and documented lab trials to support U.S. field acceptance.
A hardened 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 support covers scheduling/logistics/after-sales so your deployment remains on plan.
Contact Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every shipment with laboratory validation and responsive service.