Fiber-to-the-Home Cable Production: Manufacturing Process Explained
Quick fact: over seventy percent of U.S. broadband rollouts now use fiber networks that need precise manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment manages end-to-end FTTH cable production line manufacturing, from selecting brand fibers like Fujikura® or Corning SMF-28e to complete test reports that guarantee full quality assurance.
Our FTTH drop designs suit overhead, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and PE jacket options and configurations from 1–4 cores. We supply single-mode OS1/OS2 and OM2–OM4 grades plus G.652D and G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automation and precision equipment keep line speed steady and keep repeatability high. Typical lead times run 4–5 days for orders under 100 km and 7–10 days under 500 km, with an min. order of 1 km and warranty covering free replacement for confirmed quality issues.
Read on to see how materials, testing, and support work together to reduce lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment provides end-to-end manufacturing and lab testing for U.S. deployments.
- Multiple jacket choices and optical grades support different install environments.
- Automated production lines provide consistent quality and stable optical performance.
- Fast lead times, low minimums, and brand fiber options keep procurement predictable.
- Comprehensive test reports and after-sales warranty support product reliability and compliance documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment delivers tailored drop solutions with complete test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment combines specialized equipment with tight material control. We offer customized service and products for single-family and MDU rollouts. Every order includes full QA coverage and complete test reports.
Our lab conducts high-temperature, salt spray, and vibration testing to verify durability. Jacket options cover LSZH, PVC, and PE. Designs cover flat bow-type 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 fully auditable shipments.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixturing and calibration minimize variation so every cable meets carrier standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with strict test routines.
Fiber Selection & Brand Options
We align fiber draw tower to minimum bend radius, loss, and deployment type. Options include OS1/OS2 and 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 preferred where non-conductive runs are required. Steel wire provides tensile strength for long-span aerial runs and grounding needs.
Jacket extrusion and process control
Jacket options include LSZH for indoor flame safety, PVC for flexibility, and PE for UV/moisture resistance outdoors. Closed-loop control of extruder temperature and capstan speed stabilizes line speed and critical dimensions.
| Member | FRP | Metallic Steel |
|---|---|---|
| Primary use | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Lightweight, inert | Very high tensile strength |
| Installer note | Simple terminations | Bonding/grounding required |
In-Process and Final Testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests confirm attenuation and return loss. Each order ships with a 100% test report and lab results from high-temperature, salt-spray, and vibration trials to qualify field handling and drop terminations.
Typical lead times are under 100 km in 4–5 days and under 500 km in 7–10 days. Lot records and FAI approvals support traceability and compliance for U.S. programs.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment provides a focused portfolio of 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 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 dielectric FRP for non-conductive runs or steel wire when bonding and extra tensile strength are required.
Strength member and core layouts
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 Fiber draw tower 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 validated for mechanical and optical quality before shipment.
| Type | Best use | Strength element | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | Dielectric FRP | LSZH |
| Self-supporting (aerial) | Overhead spans | FRP/Steel | PE |
| Central loose-tube | Higher-count builds | Dielectric FRP | LSZH/PE |
| Flat unitube | Low count, quick strip | FRP/Steel | LSZH/PE |
Equipment Ensuring Quality and Throughput
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for drop patch preparation.
Our production line uses automated machines that cut and strip drop patch cords to increase output and cut labor variability.
The CLX-BPO2 automated stripper runs under PLC and photoelectric control. One cycle is about 1.5 seconds, giving ~20 terminals per minute in production.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH and PVC jackets and trims FRP or steel strength members to precise stub lengths. Cylinder-driven actuators provide quick, repeatable motion and minimize downtime.
PLC & Photoelectric for Precision
PLC logic + photoelectric sensors give exact positioning and closed-loop control. Inline checks update SPC charts so operators can adjust drifts before defects grow.
| Item | Capability | Benefit |
|---|---|---|
| CLX-BPO2 | 1.5s cycle, auto-strip | High throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Materials | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Process control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic loading keep the line clean.
- Process control plans document calibration and key parameters.
- Integrated assets and trained operators support FTTH volume targets without sacrificing accuracy.
CLX-BPO2 Capabilities on Our Line
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 raise output and standardize terminal 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 keeps strip and stub lengths within tight tolerances.
Line Speed
Typical operation speed is 1.5s per cycle. This converts to steady throughput under continuous line conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets 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.
FRP & Steel Member Handling
The machine cleanly cuts FRP and steel wire strength elements while protecting adjacent fibers. Customized cutters are available for non-standard cross-sections to maintain precision.
- Automatic waste ejection and sensor-triggered start cut idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass simplify cell integration.
- Pneumatic cylinders and PLC/photoelectric control improve line reliability and lower maintenance interruptions.
| Specification | Rating | Why it matters |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5–35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0–11.0 mm | Supports termination strength |
| 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.
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 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 and G.657 variants to align with optics and connector plans.
We match sheath colors to Pantone codes for quick field identification and consistent asset tags.
Jacket materials, print legends, and branding
Select LSZH, PVC, or PE jackets based on route and safety rules. Custom legends/logos aid inventory/warranty tracking.
Put-Ups, Packaging, and Structures
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 FRP or steel members to meet span and isolation needs.
| Option | Common choice | Advantage |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Less staging, easier reels |
| Sheath | LSZH / PE / PVC | Indoor/Outdoor fit |
| Structure | Flat bow / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and provides docs 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.
Environmental and Mechanical Tests
Our lab runs elevated-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials and assemblies. These tests simulate field stresses for indoor/outdoor applications.
Per-Reel 100% Reports
Every fiber optic cable ships with a 100% test report that logs attenuation, return loss, and geometry where applicable. Final inspection gates stop nonconforming items before they leave the factory.
Audit Trail and Compliance
Lot/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.
- In-line checks plus final inspection reduce field failures and cut warranty events.
- Quality packages include spec confirmation and formatted data for rapid review.
- Continuous test trends drive preventive maintenance and improve long-term reliability.
| Test | Purpose | Result |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt spray | Corrosion resistance | Qualified for outdoor use |
| Vibration | Resistance to vibration | Reduced field failures |
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 vary widely—from about $30 to $1,000 per unit—based on fiber grade, jacket chemistry (LSZH, PVC, PE), length, and structural design.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber optic grade, jacket material, and the structural type chosen for deployment.
Self-supporting designs and steel members increase material/labor. 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. Small quantities often include setup charges and higher per-unit charges.
- 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.
- Framework agreements and indexed pricing stabilize budgets across phases.
| Factor | Price impact | Guidance |
|---|---|---|
| Fiber grade | Large | Balance spec vs. budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Order length / volume | High impact | Consolidate runs to cut unit cost |
Logistics for the U.S.
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align crews and sites. Predictable schedules cut downtime and help control cost when a rollout is underway.
Typical production windows and capacity planning
Typical production windows are 4–5 days for < 100 km and 7–10 days for orders under 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 can plan arrivals. For tight schedules, we hold contingency capacity to accelerate critical-path orders.
MOQ and Rationale
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 length and staging plans to choose reel sizes that cut waste and handling. Batch releases can balance inventory holding with more frequent small-site deliveries.
Where and How to Deploy
On-site conditions dictate whether a self-supporting span, 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 recommends 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 riser/plenum distribution and ONT termination
Indoor riser and plenum routes prefer LSZH to meet flame and smoke rules. Flat drop profiles strip clean and present controlled stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding requirements, lightning exposure, and hardware fit. Standardized line prep shortens install time and minimizes scrap.
| Deployment | Key design | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Duct | Low-friction jacket, crush resistance | Use pull tape + lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow local depth and warning tape rules |
| Interior | 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.
Comprehensive Support & After-Sales
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 deliver documentation 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 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 requirements every time.
| Area | Scope | Benefit |
|---|---|---|
| Engineering | Specs + pilots | Reduced field issues |
| QA/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 deliver customized FTTH drop solutions that combine materials with validated manufacturing and lab tests. Every reel ships with a 100% test report and documented lab trials to support U.S. field acceptance.
A robust production line, including CLX-BPO2-enabled prep machines, cuts variability and shortens turnaround. Our equipment set standardize strip and 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.
Get in touch with Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every shipment with laboratory validation and responsive service.