FTTH Cable Production: Step-by-Step Manufacturing Process
Did you know: more than seventy percent of new U.S. broadband builds now use fiber networks that demand tight manufacturing control to achieve required performance.
Shanghai Weiye OFC Equipment runs end-to-end fiber secondary coating line manufacturing, from selecting brand fibers like Fujikura® or Corning® SMF-28e to complete test reports that deliver 100% QA.
Our FTTH drop designs fit aerial, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), PVC, and polyethylene (PE) jacket options and arrangements from 1–4 cores. We supply single-mode OS1/OS2 and multimode OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automation and high-precision equipment keep line speed steady and keep repeatability high. Typical lead times are four to five days for orders < 100 km and seven to ten days under 500 km, with an min. order of 1 km and free-replacement warranty for quality problems.
Keep reading to understand how materials, testing, and support combine to lower lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment provides full manufacturing with lab validation for United States projects.
- Multiple jacket choices and optical grades support different install environments.
- Automated production lines deliver consistent quality and stable optical performance.
- Quick lead times, low minimums, and brand fiber options support reliable procurement planning.
- Complete reports and after-sales 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 delivers tailored drop solutions with complete test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment combines specialized equipment with tight material control. We offer customized service and products for residential and MDU rollouts. Every order comes with full QA coverage and full test reports.
Our lab runs high heat, salt-fog, and vibration tests to verify durability. Jacket options cover LSZH, PVC, and PE. Designs cover bow-type flat and figure-8/self-supporting styles and use brand fibers such as Fujikura and Corning® SMF-28e.
- Documented line control and in-process checks for auditable shipments.
- Technical support for specs, trials, and ramp to volume.
- Modern fixtures and calibration reduce variability so every cable matches operator specs.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are built around network requirements, pairing brand fiber choices with disciplined test flows.
Optical fiber selection and brand options
We match fiber ribbon line to bend radius, loss, 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 available to meet procurement standards.
Strength member integration
Strength members employ dielectric FRP or metallic steel wire. FRP is ideal where non-conductive runs are required. Steel wire provides tensile strength for longer aerial spans and grounding needs.
Jacket extrusion and 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. Tight process control of extruder temperature and capstan speed stabilizes line speed and critical dimensions.
| Component | FRP | Steel wire |
|---|---|---|
| Use case | Electrical isolation | High-tension aerial runs |
| Advantage | Lightweight, inert | Very high tensile strength |
| Installation note | Easier terminations | Bonding/grounding required |
Testing & Verification
Inline geometry/concentricity checks run during manufacturing. Final optical tests verify attenuation and return loss. Each order ships with a full test report and lab results from high-temperature, salt-spray, and vibration tests 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 first-article approvals support traceability and compliance for U.S. programs.
FTTH drop cable types and structures we manufacture
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 include a messenger element to handle tension. Choose FRP (dielectric) for electrical isolation or steel messenger when bonding/grounding and higher tensile strength are required.
Core Layouts and Strength Members
We provide both 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 durability. Each family is validated for mechanical/optical performance before shipment.
| Design | Application | Strength member | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | FRP (dielectric) | LSZH |
| Self-supporting (aerial) | Overhead spans | FRP/Steel | PE |
| Central loose-tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Unitube flat | Low-count, easy strip | FRP or steel | LSZH/PE |
Production line equipment that ensures quality and speed
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 and strip drop patch cords to raise throughput and cut labor variability.
The CLX-BPO2 automated stripper uses PLC + photoelectric control. One cycle is about 1.5 seconds, giving real-world speeds near 20 terminal operations per minute.
Auto Cut & Strip Capabilities
The equipment strips LSZH and PVC jackets and trims FRP/steel members to precise reserved lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and low downtime.
PLC & Photoelectric for Precision
PLC logic + photoelectric sensors give exact positioning and closed-loop control. Inline checks feed control charts so operators can adjust drifts before out-of-control conditions occur.
| Feature | Capability | Result |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Materials | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic feeders maintain clean workcells.
- PCPs document calibration and key parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets without compromising accuracy.
CLX-BPO2 Capabilities on Our Line
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, reducing cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment deploys the CLX-BPO2 to increase throughput and standardize prep quality. The unit runs at an approximate cycle time of 1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC/photoelectric control deliver exact detection and repeatable motion. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Cycle time and throughput
Typical operation speed is 1.5s per cycle. This converts to steady throughput under normal production conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets 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 cuts FRP/steel strength elements cleanly while protecting adjacent fibers. Customized cutters 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 boost reliability and reduce maintenance downtime.
| Spec | Rating | Benefit |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5 to 35.0 mm | Fits common connector processes |
| Stub (B) | 7.0–11.0 mm | Meets strength and termination needs |
| Power & size | 50W @ 110–220V; 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.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures each build to meet 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 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 tags.
Jacket materials, print legends, and branding
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom legends/logos support inventory and warranty tracking.
Put-Ups, Packaging, and Structures
Standard reel lengths are 1 km, 2 km, and 4 km with tailored reels and packaging to fit storage/handling. Choose flat bow-type or self-supporting and steel wire or FRP strength members to meet span and isolation needs.
| Choice | Common choice | Benefit |
|---|---|---|
| Length | 1, 2, or 4 km | Less staging, easier reels |
| Sheath | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Design | Bow-type / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye schedules runs to your plan and delivers documentation that lists final specifications for straightforward QA on site.
Quality assurance, testing, and documentation
Shanghai Weiye OFC Equipment builds checkpoints into production so every item has recorded acceptance data at ship.
Lab Testing: Heat, Salt Spray & Vibration
Our lab runs high-temperature exposure, salt fog corrosion, and vibration tests to qualify materials and assemblies. These tests simulate field stresses for indoor/outdoor applications.
100% test reports for every cable
Every fiber optic cable includes a 100% test report that records loss, return loss, and key geometry where applicable. Final inspection gates stop nonconforming items before they leave the factory.
Audit Trail and Compliance
Lot/batch records tie test data to reels and serials so audits and warranty claims are simple to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- Line checks and final inspection reduce field failures and cut warranty events.
- QA packages include specifications confirmation and formatted data for rapid review.
- Ongoing trend analysis drive preventive maintenance and improve long-term reliability.
| Trial | Purpose | Result |
|---|---|---|
| Heat exposure | Thermal stability | Validated heat endurance |
| Salt-fog | Corrosion resistance | Qualified for outdoor use |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
Pricing and cost drivers for FTTH drop cable
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 structural design.
Primary Cost Inputs
The primary cost drivers are fiber grade, jacket material, and the chosen structure for deployment.
Self-supporting structures and steel members increase material/labor. Custom colors, logos, and print legends add setup time and impact pricing on small runs.
How Volume & Options Affect Cost
Longer put-ups and larger volumes 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.
| Driver | Price impact | Guidance |
|---|---|---|
| Optical grade | High impact | Right-size spec to budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Order 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 windows reduce downtime and control costs when a rollout is underway.
Production Windows & Capacity
Typical production windows are 4–5 days for < 100 km and 7–10 days for orders under 500 km. We schedule line capacity to match your rollout milestones and to maintain on-time delivery.
The service team provides updates/tracking so installation teams know when reels arrive. For tight schedules, we hold contingency capacity to pull in critical-path orders.
Minimum order quantity and why it 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 put-ups and staging to select reels to reduce waste/handling. Batch releases can balance inventory with more frequent small-site deliveries.
Installation readiness and application scenarios
Site conditions determine whether a self-supporting span, duct pull, or direct-buried run is the best fit for a project.
Aerial vs Duct vs Direct-Buried
For aerial runs, Shanghai Weiye OFC Equipment advises self-supporting designs with appropriate 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 is needed.
Direct-buried designs require proper depth control per local codes and moisture barriers to protect the optic core over time.
Indoor riser/plenum distribution and ONT termination
Indoor riser and plenum routes prefer LSZH to meet flame and smoke rules. Flat drop profiles strip cleanly and present controlled stubs for fast ONT terminations.
We guide the choice of steel or FRP (dielectric) strength members based on bonding needs, lightning exposure, and hardware compatibility. Standardized prep from the production line shortens install time and minimizes scrap.
| Deployment | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct burial | PE with moisture barrier | Follow depth/warning tape codes |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience 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 testing, scheduling, 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 test reports and traceability to support QA acceptance.
- Round-the-clock availability for status updates and technical guidance.
- Warranty with free replacement if any quality problems are confirmed.
- Coordination of line schedules for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed requirements every time.
| Area | What we do | Outcome |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| Testing | Lab + 100% reports | Full traceability |
| Service | Rapid replacement & root-cause | Minimized downtime |
Wrap-Up
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 trials to support U.S. field acceptance.
A robust production line, including CLX-BPO2-enabled prep machines, reduces variability and speeds turnaround. Our equipment set standardize strip and stub lengths so installers see consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance design and cost to extend 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 specs, timeline, and volume. We stand behind every shipment with lab validation and responsive service.