FTTH Cable Production: How the Manufacturing Process Works
Surprising fact: more than seventy percent of new U.S. broadband builds now use fiber networks that require precise manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment handles end-to-end Fiber cable sheathing line manufacturing, from choosing brand fibers like Fujikura® or Corning SMF-28e to comprehensive test documentation that guarantee full quality assurance.
Our FTTH drop designs fit overhead, underground, and direct burial installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and polyethylene (PE) jacket options and configurations from 1 to 4 cores. We provide OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone sheath colors, and custom logo printing.
Automation and high-precision equipment stabilize line speed and repeatability high. 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 warranty for free replacement on quality issues.
Read on to understand how materials plus testing and support help reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment provides end-to-end manufacturing and lab testing for U.S. deployments.
- Multiple jacket choices and optical grades cover varied installation environments.
- Automated lines and machines ensure stable quality and reliable optical performance.
- Fast lead times, low minimums, and recognized brand fibers keep procurement predictable.
- Complete reports and warranty back product reliability and compliance documentation needs.
Expert FTTH manufacturing 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 dedicated manufacturer, Shanghai Weiye OFC Equipment combines purpose-built equipment with tight material control. We offer customized service and products for residential and MDU rollouts. Every order includes full QA coverage and complete test reports.
Our lab conducts high heat, salt spray, and vibration tests to validate durability. Jacket options cover LSZH, PVC, and PE. Designs offer bow-type flat 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.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixturing and calibration reduce variability so every cable matches operator specs.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, combining brand fiber choices with disciplined test flows.
Optical fiber selection and brand options
We select fiber draw tower to bend radius, loss, 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.
Integrating Strength Members
Strength members use FRP (dielectric) 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 indoor flame safety, PVC for flexibility, and PE for UV/moisture resistance outdoors. Tight process control of extruder temperature and capstan speed stabilizes line speed and critical dimensions.
| Component | FRP | Steel wire |
|---|---|---|
| Use case | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Light, non-corrosive | Very high tensile strength |
| Installation note | Simple 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 confirm handling for drop terminations and field use.
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. programs.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment provides a focused portfolio of FTTH drop designs that fit indoor risers and long aerial runs. Each option pairs tested materials with geometry tuned for field termination and consistent optical performance.
The bow-type flat drop cable minimizes footprint for risers and conduit. It reduces bend loss for simple routing in hallways and MDUs.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs use a messenger element to handle tension. Choose dielectric FRP for non-conductive runs or steel wire when bonding and higher tensile strength are required.
Layouts & Strength Members
We provide both dielectric and metallic strength member configurations to match safety and EMI rules. Center loose tube and flat unitube types balance crush resistance and fiber secondary coating line for fast terminations.
Indoor/outdoor jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each series is qualified for mechanical and optical quality before shipment.
| Type | Application | Strength element | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting | Aerial spans | FRP/Steel | Polyethylene |
| Central loose-tube | Higher-count builds | Dielectric FRP | LSZH/PE |
| Unitube flat | Low count, quick strip | FRP/Steel | LSZH/PE |
Production Assets for Speed and Quality
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 about 1.5 seconds, 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 provide quick, repeatable motion and low downtime.
Closed-Loop Control for Repeatability
PLC logic + photoelectric sensors give exact positioning and feedback control. Inline checks update SPC charts so operators can correct trends before out-of-control conditions occur.
| Item | Capability | Benefit |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Actuation | Pneumatic cylinders | High speed and reliability |
| Materials | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic feeders keep the line clean.
- 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 provides industrial-grade strip/trim to our line, reducing cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment deploys the CLX-BPO2 to raise output 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 and photoelectric control enable precise detection and repeatable motion. 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 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 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. Customized cutters are available for non-standard cross-sections to preserve precision.
- Automatic waste ejection and sensor start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass ease integration into workcells.
- Pneumatic cylinders and closed-loop control boost reliability and lower maintenance interruptions.
| Specification | Rating | Benefit |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (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 terminal prep so field teams get drop parts install-ready. The CLX-BPO2 helps our production lines meet volume goals without sacrificing quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures every order to meet your network requirements and simplify field rollout. We pair concise options with predictable manufacturing windows so your teams get install-ready reels.
Choose 1 to 4 cores with single-mode or multimode 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 tagging.
Branding and Print Options
Select LSZH/PVC/PE jackets based on route and safety rules. Custom print legends and logos aid inventory/warranty tracking.
Length options, packaging, and special structures
Standard put-ups are 1/2/4 km with custom reels and packaging to fit storage/handling. Choose bow-type flat or self-supporting designs and steel wire or FRP strength members to meet span and isolation needs.
| Option | Common choice | Advantage |
|---|---|---|
| Length | 1 / 2 / 4 km | Less staging, easier reels |
| Sheath | LSZH / PE / PVC | Indoor/Outdoor fit |
| Structure | Bow-type / Self-supporting | Flexible routing/span |
As a supplier, Shanghai Weiye aligns runs to your schedule and delivers documentation that detail final specs for easy on-site QA.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment builds checkpoints into production so every item has recorded acceptance data at ship.
High-temperature, salt spray, and vibration laboratory testing
Our lab runs elevated-temperature exposure, salt spray corrosion, and vibration tests to qualify materials/assemblies. These tests recreate field stresses for indoor/outdoor applications.
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 inspection gates stop nonconforming items before they leave the factory.
Traceability and compliance
Batch records tie test data to reels and serials so audits and claims are easy to verify. Documentation follows common customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection prevent field failures and lower warranty events.
- Quality packages include spec confirmation and formatted data for quick review.
- Ongoing trend analysis drive preventive maintenance and improve long-term reliability.
| Trial | Purpose | Result |
|---|---|---|
| Heat exposure | Material stability | Pass at target temperature |
| Salt-fog | Corrosion resistance | Outdoor suitability |
| Mechanical vibration | Mechanical robustness | Reduced field failures |
FTTH Drop Cable Pricing & Cost Drivers
Budget planning for a drop 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.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber optic grade, sheath material, and the structural type chosen for deployment.
Self-supporting structures and steel members increase material/labor. Custom colors, logos, and print legends add setup time and influence price for short runs.
Length/Volume/Customization Impact
Longer reels and higher volume orders reduce unit cost. Short runs often include setup charges and higher unit prices.
- Line changeovers and custom tooling extend lead time and add cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets over phases.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Fiber grade | Large | Balance spec vs. budget |
| Sheath material | Medium impact | Compare LSZH vs. PE for total cost |
| Order length / volume | Large | Consolidate runs to cut unit cost |
Logistics for the U.S.
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.
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 match your rollout 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.
Minimum order quantity and why it matters
The MOQ is one kilometer. This reflects line setup such as wire/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 with more frequent small-site deliveries.
Where and How to Deploy
Site conditions determine whether a self-supporting span, ducted pull, or direct-buried run is the best fit for a project.
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 sheaths 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-resistant jackets to protect the fiber core long-term.
Indoor Distribution and ONT
Indoor riser/plenum routes favor LSZH jackets to meet flame and smoke rules. Flat drop cable forms strip clean and present controlled strength stubs for quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding needs, lightning exposure, and hardware fit. Standardized line prep reduces install time and reduces scrap.
| Deployment | Key feature | Installer note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Underground duct | Low-friction jacket, crush resistance | Use pull tape + 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, speeds activations, and reliable field performance for your system.
Support from Spec to Service
Our team coordinates testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements capture through approved drawings and pilot builds. We provide doc templates and clear installation notes so field crews share a unified plan.
After-sales service covers rapid response, root-cause analysis, and corrective actions. All products ship with full reports and traceability to support QA acceptance.
- 24/7 availability for status and technical support.
- Warranty includes free replacement for confirmed quality issues.
- Coordination of line schedules for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed specs consistently.
| Area | What we do | Benefit |
|---|---|---|
| Tech/Eng | Specs + pilots | Reduced field issues |
| QA/Testing | Lab + 100% reports | Traceable quality |
| Service | Rapid replacement & root-cause | Lower 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 includes a 100% test report and documented lab trials to support field acceptance in the United States.
A robust production line, including CLX-BPO2 prep assets, 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 performance and cost to maximize service life. Dedicated support covers scheduling/logistics/after-sales so your deployment remains on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with laboratory validation and responsive support.