FTTH Cable Production: How the Manufacturing Process Works
Surprising fact: in excess of 70% of new broadband deployments in the U.S. now depend on fiber networks that need precise manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment handles end-to-end Fiber cable sheathing line manufacturing, from sourcing brand fibers like Fujikura or Corning SMF-28e to final test reports that deliver 100% QA.
Our drop designs fit overhead, ducted, and direct-buried installation, with LSZH, polyvinyl chloride (PVC), and PE jacket options and core counts from 1–4 cores. We offer OS1/OS2 and multimode OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone-matched sheath colors, and logo printing.
Automation and precision equipment stabilize line speed and keep repeatability high. Typical lead times are 4–5 days for orders under 100 km and 7–10 days under 500 km, with an MOQ of 1 km and warranty for free replacement on quality issues.
Continue to learn how materials plus testing and support help reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment delivers full manufacturing with lab validation for U.S. deployments.
- A range of jacket options and optical grades fit different install environments.
- Automated lines and machines provide consistent quality and stable optical performance.
- Fast lead times, low MOQ, and brand fiber options help plan procurement reliably.
- Comprehensive test reports and warranty support product reliability and documentation needs.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment provides tailored drop solutions with complete test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment combines specialized equipment with stringent material control. We provide custom builds and services for residential/MDU deployments. Every order comes with 100% quality assurance and complete test reports.
Our lab runs high-temperature, salt-fog, and vibration testing to validate durability. Jacket options include LSZH, PVC, and PE. Designs include flat bow-type and figure-8/self-supporting styles and support brand fibers such as Fujikura and Corning SMF-28e.
- Controlled production lines and production checks for shipments with audit trails.
- Technical support for specs, trials, and ramp to volume.
- 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 matched to network specs, pairing brand fiber choices with disciplined test flows.
Selecting Optical Fiber and Brands
We align fiber ribbon line to minimum bend radius, attenuation, and deployment type. Options include OS1, OS2, OM2–OM4 and G.652D and G.657.A1/A2 per ITU-T. Brand fibers such as Fujikura® and Corning® SMF-28e are available to satisfy sourcing standards.
Strength member integration
Strength members employ dielectric FRP or metallic steel wire. FRP is ideal where non-conductive runs are required. Steel wire adds tensile strength for longer aerial spans and bonding/grounding needs.
Extrusion & Process Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility and ease of handling, and PE for outdoor UV and moisture resistance. Closed-loop control of extruder temperature and capstan speed keeps line speed stable and dimensional tolerances.
| Component | FRP | Steel wire |
|---|---|---|
| Primary use | Non-conductive runs | Aerial spans, high tensile |
| Advantage | Lightweight, inert | High strength |
| Installation note | Easier terminations | Bonding/grounding required |
Inline and final testing
Inline geometry and concentricity checks operate in-line. Final optical tests confirm attenuation and reflectance. Each order includes a full 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 under 500 km in 7–10 days. Material lot records and FAI approvals provide traceability and compliance for U.S. programs.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment provides a compact portfolio of FTTH drop designs that suit both tight indoor routes and exposed aerial spans. Each option combines tested materials with field-termination geometry and consistent optical performance.
The flat bow-type drop minimizes footprint for risers and conduit. It keeps bend loss low for easy routing in hallways and MDUs.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs use a messenger element to carry tensile loads. Choose dielectric FRP for electrical isolation or steel wire when bonding and higher tensile strength are required.
Layouts & Strength Members
We provide dielectric and metallic strength member configurations to match safety and EMI rules. Central loose-tube and flat unitube types balance crush resistance and fiber ribbone line for quick termination.
Indoor/outdoor jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each series is validated for mechanical/optical performance before shipment.
| Type | Application | Strength element | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting | Overhead spans | Steel wire or FRP | PE |
| Center loose tube | Higher fiber counts | FRP | LSZH/PE |
| Unitube flat | Low count, quick strip | FRP or steel | LSZH/PE |
Equipment Ensuring Quality and Throughput
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment reduce manual handling and boost 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 uses PLC + photoelectric control. One cycle is ~1.5 s, giving ~20 terminals per minute in production.
Automated Cut/Strip for Drop Cords
The equipment strips LSZH and PVC jackets and trims FRP or steel strength members to precise stub lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and low downtime.
PLC/photoelectric control for precision and repeatability
PLC logic and photoelectric sensors deliver precise positioning and feedback control. Inline checks update SPC charts so operators can correct trends before defects grow.
| Feature | Capability | Result |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Drive | Pneumatic cylinders | Fast/reliable motion |
| Materials | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Process control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic feeders keep the line clean.
- PCPs capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without sacrificing 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 uses the CLX-BPO2 to increase throughput 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 enable precise detection and repeatable motion. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Line Speed
Typical operation speed is 1.5s per cycle. This translates to steady throughput under continuous line conditions.
Supported Strip and 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 match common termination hardware.
Cutting FRP/Steel Members
The machine cleanly cuts FRP and steel wire strength elements while protecting adjacent fibers. Custom tooling are offered for non-standard cross-sections to preserve precision.
- Auto-eject scrap and sensor start cut idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight ease integration into workcells.
- Cylinder-driven motion and PLC/photoelectric control improve line reliability and reduce maintenance downtime.
| Spec | Rating | Why it matters |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | Supports high-volume runs |
| Strip lengths (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Reserved stub (B) | 7.0–11.0 mm | Meets strength and termination needs |
| Power/Size | 110–220V, 50W; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes terminal prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 helps our production lines meet volume goals without sacrificing 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 get install-ready reels.
Choose 1–4 core designs with SM or MM 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 tagging.
Branding and Print Options
Select LSZH/PVC/PE jackets based on route and safety rules. 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 fit storage/handling. Choose flat bow-type or self-supporting and FRP or steel members to meet span and isolation needs.
| Choice | Typical | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and reels |
| Sheath | LSZH, PE, PVC | Indoor/Outdoor fit |
| Structure | Flat bow / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye schedules runs to your plan and provides docs that lists final specifications for straightforward QA on site.
QA, Testing & Documentation
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 spray corrosion, and mechanical vibration to qualify materials/assemblies. These tests simulate field stresses for indoor and outdoor use.
Per-Reel 100% Reports
Every fiber optic cable includes a 100% test report that records loss, return loss, and key geometry where applicable. Final inspection gates prevent nonconforming shipments before they leave the factory.
Audit Trail and Compliance
Lot/batch records tie test data to reels and serials so audits and claims are easy to verify. Documentation follows common customer templates to accelerate approvals and receiving inspection.
- Line checks and final inspection reduce field failures and lower warranty events.
- QA packages include specifications confirmation and formatted data for rapid review.
- Ongoing trend analysis drive preventive maintenance and raise long-term reliability.
| Test | Purpose | Outcome |
|---|---|---|
| High-temperature | Material stability | Pass at target temperature |
| Salt-fog | Corrosion robustness | Qualified for outdoor use |
| Vibration | Resistance to vibration | Improved field reliability |
FTTH Drop Cable Pricing & Cost Drivers
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 to $1,000 per unit—based on fiber grade, jacket material, reel length, and design structure.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, sheath material, and the structural type chosen for deployment.
Self-supporting designs and steel members raise material and labor input. Custom sheath colors/logos/legends add setup and influence price for short runs.
Order length, volume, and customization impact on price
Longer put-ups and larger volumes lower unit cost. Short runs often carry setup fees and higher unit prices.
- 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.
- Framework agreements and indexed pricing stabilize budgets across phases.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Optical grade | High impact | Right-size spec to budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Length/Volume | High impact | Consolidate where possible |
Logistics for the U.S.
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align staffing and sites. Predictable windows cut downtime and control costs 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 plan capacity to track your milestones and to maintain on-time delivery.
The service team provides updates/tracking so installation teams can plan arrivals. For tight schedules, we reserve contingency capacity to pull in critical-path orders.
MOQ and Rationale
The MOQ is 1 km. This reflects setup needs 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 holding with frequent, smaller deliveries to job sites.
Where and How to Deploy
Site conditions determine whether a self-supporting aerial, duct pull, or direct-buried run is the right choice for a project.
Deployment Considerations
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with appropriate members to manage sag/tension for long-term reliability.
Duct installations work best with low-friction jackets and crush-resistant constructs so pulling avoids fiber damage. PE jackets are common 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 Distribution and ONT
Indoor riser and plenum routes prefer LSZH to meet flame and smoke rules. Flat drop cable forms strip cleanly and present controlled stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding requirements, lightning risk, and hardware fit. Standardized line prep reduces install time and minimizes scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Underground duct | Low-friction, crush-resistant | 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 penetrations |
Our approach delivers a consistent installation across indoor outdoor transitions. That leads to fewer callbacks, speeds activations, and reliable field performance for your system.
Support from Spec to Service
Our team coordinates tests, line schedules, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment provides 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 covers rapid response, root-cause analysis, and corrective actions. All products ship with full 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 specs consistently.
| Support area | What we do | Outcome |
|---|---|---|
| Tech/Eng | Specs + pilots | Reduced field issues |
| Testing | Lab + 100% reports | Full traceability |
| Service | Fast replace + RCA | Minimized downtime |
Conclusion
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 ships with a 100% test report and documented trials to support field acceptance in the United States.
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 through jacket, printing, and packaging, we balance performance and cost to maximize service life. Dedicated customer support guides scheduling, logistics, and after-sales care so your deployment remains on plan.
Contact Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with laboratory validation and responsive support.