FTTH Cable Production: Step-by-Step Manufacturing Process
Surprising fact: in excess of 70% of new broadband deployments in the U.S. now rely on fiber networks that need tight manufacturing control to meet performance goals.
Shanghai Weiye OFC Equipment runs full-cycle FTTH cable production line manufacturing, from sourcing brand fibers like Fujikura® or Corning® SMF-28e to final test reports that guarantee full quality assurance.
Our FTTH drop designs are built for aerial, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and polyethylene (PE) jacket options and core counts from 1 to 4 cores. We provide OS1/OS2 and multimode OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone sheath colors, and custom logo printing.
Automated machines and precision equipment stabilize line speed and repeatability high. Typical lead times run four to five 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.
Continue to see how materials plus testing and support combine to lower lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment provides end-to-end manufacturing and lab testing for United States projects.
- Multiple jacket choices and optical grades cover varied installation environments.
- Automated production lines ensure stable quality and reliable optical performance.
- Fast lead times, low minimums, and recognized brand fibers keep procurement predictable.
- Comprehensive test reports and warranty back product reliability and documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment provides customized drop cables with complete test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment pairs purpose-built equipment with tight material control. We offer custom builds and services for residential/MDU deployments. Every order includes 100% quality assurance and complete test reports.
Our lab runs high-temperature, salt spray, and vibration tests to verify durability. Jacket options cover LSZH, PVC, and PE. Designs include bow-type flat and figure-8/self-supporting styles and support brand fibers such as Fujikura and Corning® SMF-28e.
- Documented line control and production checks for fully auditable shipments.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixturing and calibration minimize variation so every cable meets carrier standards.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, pairing brand fiber choices with strict test routines.
Fiber Selection & Brand Options
We align fiber ribbon line to minimum bend radius, loss, 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 satisfy sourcing standards.
Strength Member Options
Strength members employ FRP (dielectric) or metallic steel wire. FRP is preferred where non-conductivity is necessary. Steel wire provides 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. Closed-loop control of temperature and capstan ratios keeps line speed stable and dimensional tolerances.
| Member | FRP | Steel wire |
|---|---|---|
| Use case | Non-conductive runs | High-tension aerial runs |
| Key benefit | Light, non-corrosive | High strength |
| Installer note | Easier terminations | Requires grounding |
Inline and final testing
Inline geometry and concentricity checks operate in-line. Final optical tests confirm attenuation and return loss. Each order includes a 100% test report and lab results from high heat, salt-spray, and vibration trials to qualify field handling and drop terminations.
Typical lead times are 4–5 days for < 100 km and 7–10 days for < 500 km. Material lot records and FAI approvals support traceability and compliance for U.S. programs.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment provides a focused portfolio of drop designs that cover 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/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 FRP (dielectric) for non-conductive runs 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 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 durability. Each series is validated for mechanical/optical performance before shipment.
| Design | Application | Strength member | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting | Overhead spans | Steel wire or FRP | PE |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH or PE |
| Flat unitube | Low count, quick strip | FRP or steel | LSZH or PE |
Production Assets for Speed and Quality
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and increase throughput for patch cord prep.
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/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 and photoelectric sensors deliver precise positioning and feedback control. Inline checks feed control charts so operators can adjust drifts before defects grow.
| Feature | Spec | Result |
|---|---|---|
| CLX-BPO2 | 1.5s cycle, auto-strip | High throughput |
| Drive | Pneumatic cylinders | High speed and reliability |
| Materials | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Automated waste ejection and ergonomic feeders maintain clean workcells.
- 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 brings industrial-grade stripping and trimming to our line, cutting cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment deploys the CLX-BPO2 to increase throughput and standardize terminal quality. The unit cycles in ~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.
Supported jacket and reserved strength lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable strip length from 17.5 to 35.0 mm. Reserved strength member stubs are set between 7.0 and 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 start cut idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight simplify cell integration.
- Cylinder-driven motion and PLC/photoelectric control boost reliability and reduce maintenance downtime.
| Specification | Rating | Why it matters |
|---|---|---|
| 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 | 110–220V, 50W; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes terminal 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 meet your network requirements and simplify field rollout. We combine focused options with predictable schedules 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 align with optics and connector plans.
We Pantone-match sheath colors for quick field identification and consistent asset tags.
Branding and Print Options
Select LSZH, PVC, or PE jackets based on route and safety rules. Custom print legends and logos support inventory and warranty tracking.
Lengths, Packaging & Special Builds
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 | Common choice | Benefit |
|---|---|---|
| Reel length | 1, 2, or 4 km | Less staging, easier 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 delivers documentation 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 fog corrosion, and mechanical vibration 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 stop nonconforming items before they leave the factory.
Traceability & Compliance
Lot/batch records tie test data to reels and serials so audits and warranty claims are simple to verify. Documentation follows common customer templates to speed approvals and inbound inspection.
- Line checks and final inspection prevent field failures and lower warranty events.
- QA packages include specifications confirmation and formatted data for quick review.
- Continuous test trends inform preventive maintenance and raise long-term reliability.
| Test | Why | Result |
|---|---|---|
| Heat exposure | Material stability | Pass at target temperature |
| Salt-fog | Corrosion resistance | Qualified for outdoor use |
| Vibration | Resistance to vibration | Reduced field failures |
Pricing and cost drivers for FTTH drop cable
Budgeting for a drop run begins with fiber/jacket selection and is shaped by volume and customization.
Typical prices vary widely—from about $30–$1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket material, reel length, and structural design.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber optic 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 and impact pricing on small runs.
How Volume & Options Affect Cost
Longer put-ups and larger volumes 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 and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets over phases.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Optical grade | Large | Balance spec vs. budget |
| Sheath material | Medium impact | Evaluate LSZH vs PE |
| 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 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 compressed schedules, we hold contingency capacity to accelerate critical-path orders.
Minimum order quantity and why it matters
The MOQ is 1 km. This reflects line setup such as wire and jacket die adjustments that consume start-up material and scrap.
We review your length and staging plans to select reels to reduce waste/handling. Staggered batches can balance inventory holding with frequent, smaller deliveries to job sites.
Installation readiness and application scenarios
On-site conditions dictate whether a self-supporting aerial, ducted pull, or direct-buried run 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 correct strength 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 typical for underground and buried paths where moisture resistance is needed.
Direct-buried designs need correct burial depth per local codes and moisture-resistant jackets to protect the optic core over time.
Indoor riser/plenum distribution and ONT termination
Indoor riser and plenum routes prefer LSZH to meet smoke/flame codes. Flat drop profiles strip cleanly and present controlled stubs for fast ONT terminations.
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 | Field note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow local depth and warning tape rules |
| Interior | LSZH jacket, tight bend support | Maintain bend radius at penetrations |
Our approach ensures a consistent install experience across indoor/outdoor transitions. That leads to fewer callbacks, faster activations, and reliable field performance for your system.
End-to-end support and after-sales service
Our team coordinates testing, scheduling, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements through approved drawings and pre-production builds. We provide doc templates and clear install notes so field crews work from the same plan.
After-sales service includes fast response, RCA, and corrective action. All products ship with full test reports and traceability to help QA acceptance.
- Round-the-clock 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 | Fewer field issues |
| QA/Testing | Lab + 100% reports | Full traceability |
| Service | Fast replace + RCA | Minimized 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 combine materials with validated manufacturing and lab tests. 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 prep assets, reduces variability and shortens turnaround. Our equipment and machines standardize strip and stub lengths so installers see consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance performance and cost to extend service life. Dedicated customer support guides scheduling, logistics, and after-sales care so your deployment stays on plan.
Contact Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every fiber optic and optic cable shipment with laboratory validation and responsive support.