FTTH Cable Production: Manufacturing Process Explained
Did you know: in excess of seventy percent of U.S. broadband rollouts now rely on fiber networks that require tight manufacturing control to achieve required performance.
Shanghai Weiye OFC Equipment runs complete FTTH cable production line manufacturing, from sourcing brand fibers like Fujikura or Corning SMF-28e to comprehensive test documentation that deliver 100% QA.
Our FTTH drop designs are built for overhead, underground, and direct-buried installation, with LSZH, PVC, and PE jacket options and configurations from 1–4 cores. We provide 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.
Automated machines and precision equipment keep line speed steady and maximize repeatability. Typical lead times run 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 see how our materials, tests, and support help reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment provides end-to-end manufacturing and lab testing for United States projects.
- Multiple jacket choices and optical grades cover indoor/outdoor environments.
- Automated lines and machines deliver stable quality and stable optical performance.
- Quick lead times, low minimums, and recognized brand fibers support reliable procurement planning.
- Comprehensive test reports and after-sales warranty back product reliability and documentation needs.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment delivers tailored drop solutions with full test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment pairs 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 performs high-temperature, salt spray, and vibration testing to validate durability. Jacket options cover LSZH, PVC, and PE. Designs include flat bow-type and figure-8/self-supporting styles and use brand fibers such as Fujikura® and Corning® SMF-28e.
- Documented line control and production checks for fully auditable shipments.
- Technical support for specs, trials, and ramp to volume.
- Modern fixtures and calibration minimize variation so every cable matches operator specs.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, combining brand fiber choices with rigorous test routines.
Selecting Optical Fiber and Brands
We match fiber draw tower to 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 offered to meet procurement standards.
Integrating Strength Members
Strength members employ dielectric FRP or galvanized steel wire. FRP is ideal where non-conductive runs are required. Steel wire provides tensile strength for long-span aerial runs and grounding needs.
Extrusion & Process Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility and ease of handling, and PE for UV/moisture resistance outdoors. Tight process control of extruder temperature and capstan speed keeps line speed stable and dimensional tolerances.
| Component | FRP | Steel wire |
|---|---|---|
| Primary use | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Lightweight, inert | High strength |
| Installer note | Easier terminations | Requires grounding |
Testing & Verification
Inline geometry/concentricity checks operate in-line. Final optical tests confirm attenuation and reflectance. Each order ships with a 100% test report and lab results from high-temperature, salt-spray, and vibration tests to qualify field handling and drop terminations.
Typical lead times are under 100 km in 4–5 days and 7–10 days for < 500 km. Lot records and FAI approvals provide traceability and compliance for U.S. programs.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment provides a focused portfolio of drop designs that cover tight indoor routes and exposed aerial spans. Each option pairs tested materials with geometry tuned for field termination and stable optical performance.
The bow-type flat drop cable minimizes footprint for risers and conduit. It keeps bend loss low for simple routing in MDU corridors and hallways.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs include a support messenger to carry tensile loads. Choose FRP (dielectric) for non-conductive runs or steel wire when bonding/grounding and extra tensile strength are required.
Strength member and core layouts
We offer dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and unitube flat types balance crush resistance and fiber secondary coating line for fast terminations.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each family is qualified for mechanical and optical quality before shipment.
| Type | Application | Strength member | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting | Aerial spans | Steel wire or FRP | PE |
| Central loose-tube | Higher fiber counts | FRP | LSZH/PE |
| Unitube flat | Low count, quick strip | FRP or steel | LSZH or PE |
Production Assets for Speed and Quality
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment cut manual handling and boost throughput for patch cord prep.
Our production line integrates automated machines that cut/strip drop cords to increase output 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.
Automated Cut/Strip for Drop Cords
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise stub lengths. Pneumatic cylinder actuators provide quick, repeatable motion and low downtime.
Closed-Loop Control for 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.
| Item | Capability | Benefit |
|---|---|---|
| CLX-BPO2 | 1.5s cycle, auto-strip | High throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Materials | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Process control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Automated waste ejection and ergonomic feeders keep the line clean.
- PCPs document calibration and key parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without compromising 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 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 and photoelectric control enable precise detection and repeatable actuation. 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 continuous line conditions.
Supported jacket and reserved strength 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.
FRP & Steel Member Handling
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Customized cutters are offered for nonstandard sizes to maintain precision.
- Auto-eject scrap and sensor start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg weight ease integration into workcells.
- Pneumatic cylinders and PLC/photoelectric control boost reliability and reduce maintenance downtime.
| Spec | Rating | Why it matters |
|---|---|---|
| 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) | 7.0–11.0 mm | Meets strength and termination needs |
| Power/Size | 50W @ 110–220V; 40×18×18 cm | Easy integration into existing equipment |
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.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures each build to fit your network requirements and simplify deployment. We combine focused options with predictable schedules so your teams receive ready-to-install products.
Choose 1–4 core designs with single-mode or multimode fiber. Options include OS1/OS2 plus OM2–OM4 plus G.652D/G.657 variants to align with optics and connector plans.
We Pantone-match sheath colors for fast field ID and consistent asset tags.
Branding and Print Options
Select LSZH, PVC, or PE jackets to suit route and safety requirements. Custom legends/logos aid inventory/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 bow-type flat or self-supporting designs 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 compatibility |
| Structure | Bow-type / Self-supporting | Routing and span flexibility |
As a supplier, Shanghai Weiye schedules runs to your plan and delivers documentation that detail final specs for straightforward QA on site.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment builds checkpoints into production so every item has recorded acceptance data at ship.
Environmental and Mechanical Tests
Our lab conducts elevated-temperature exposure, salt fog corrosion, and vibration tests to qualify materials/assemblies. These tests recreate field stresses for indoor/outdoor applications.
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 stop nonconforming items before they leave the factory.
Traceability & Compliance
Batch records link tests to reels/serials so audits and claims are easy to verify. Documentation uses standard customer templates to accelerate approvals and receiving inspection.
- Line checks and final inspection reduce field failures and cut warranty events.
- Quality packages include spec confirmation and formatted test data for quick review.
- Continuous test trends drive preventive maintenance and improve long-term reliability.
| Test | Why | Result |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion robustness | Qualified for outdoor use |
| Vibration | Mechanical robustness | Improved field reliability |
Cost Drivers and Pricing
Budgeting for a drop run begins with fiber/jacket selection 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), reel length, and structural design.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber optic grade, jacket material, and the chosen structure for deployment.
Self-supporting structures and steel members increase material/labor. Custom sheath colors/logos/legends add setup time and influence price for short runs.
Order length, volume, and customization impact on price
Longer reels and higher volume orders reduce unit cost. Small quantities often include setup charges and higher unit prices.
- Line changeovers and custom tooling increase lead time and add to cost.
- Clear RFQs with schedule alignment let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets over phases.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Optical grade | Large | Balance spec vs. budget |
| Jacket type | Medium impact | Compare LSZH vs. PE for total cost |
| Order length / volume | Large | Consolidate where possible |
Lead times, MOQ, and delivery for the United States
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.
Production Windows & Capacity
Typical production windows are 4–5 days for < 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 issues production updates and tracking so installation teams can plan arrivals. For compressed schedules, we hold contingency capacity to pull in critical-path orders.
MOQ and Rationale
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.
Installation readiness and application scenarios
Site conditions determine whether a self-supporting span, ducted pull, or direct burial is the right choice for a project.
Aerial vs Duct vs Direct-Buried
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with correct strength members to control sag and tension for long-term reliability.
Duct installations perform best with low-friction sheaths and crush-resistant builds so pulling avoids fiber damage. 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-resistant jackets to protect the fiber core long-term.
Indoor Riser/Plenum & ONT
Indoor riser/plenum routes prefer LSZH to meet flame and smoke rules. Flat drop profiles 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 requirements, lightning risk, and hardware compatibility. Standardized prep from the production line shortens install time and minimizes scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Underground duct | Low-friction, crush-resistant | Use pull tape and proper lubricant |
| Direct burial | PE jacket, moisture barrier | Follow local depth and warning tape rules |
| Interior | LSZH with tight-bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor/outdoor transitions. That reduces callbacks, faster activations, and stable field performance for your system.
End-to-end support and after-sales service
Our team coordinates testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements through approved drawings and pre-production builds. We provide doc templates and clear installation notes so field crews share a unified 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 and technical support.
- Warranty includes free replacement for confirmed quality issues.
- Coordination of line schedules for expedites and urgent changes.
- Config control so shipped items match agreed specs consistently.
| Area | What we do | Benefit |
|---|---|---|
| Tech/Eng | Specs + pilots | Fewer field issues |
| QA/Testing | Lab + 100% reports | Full traceability |
| Service | Rapid replacement & root-cause | Minimized downtime |
Conclusion
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 ships with 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 set standardize strip and stub lengths so installers see consistent results at turn-up.
From fiber selection to 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 specs, timeline, and volume. We stand behind every fiber optic and optic cable shipment with lab validation and responsive support.