Fiber-to-the-Home Cable Production: Step-by-Step Manufacturing Process
Surprising fact: in excess of seventy percent of new broadband deployments in the U.S. now depend on fiber networks that need precise manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment runs complete Fiber cable sheathing line manufacturing, from choosing brand fibers like Fujikura or Corning® SMF-28e to final test reports that guarantee full quality assurance.
Our FTTH drop designs are built for overhead, underground, and direct burial installation, with low-smoke zero-halogen (LSZH), PVC, and polyethylene (PE) jacket options and configurations from 1–4 cores. We supply OS1/OS2 and multimode OM2–OM4 grades plus G.652D and G.657 variants, Pantone sheath colors, and custom logo printing.
Automation and high-precision equipment keep line speed steady and keep repeatability high. Typical lead times run 4–5 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.
Read on to learn how materials, testing, and support work together to reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment provides complete production and laboratory testing for U.S. deployments.
- A range of jacket options and optical grades fit indoor/outdoor environments.
- Automated lines and machines ensure stable quality and stable optical performance.
- Quick lead times, low minimums, and recognized brand fibers support reliable procurement planning.
- Complete reports and after-sales warranty support product reliability and compliance documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment delivers tailored drop solutions with full test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment combines purpose-built equipment with stringent material control. We offer customized service and products for residential and MDU rollouts. Every order includes 100% quality assurance and full test reports.
Our lab conducts high heat, salt-fog, and vibration tests to verify durability. Jacket options include LSZH, PVC, and PE. Designs offer bow-type flat and self-supporting styles and use brand fibers such as Fujikura and Corning SMF-28e.
- Controlled production lines and production checks for shipments with audit trails.
- Technical support for requirements, pilots, and scaling.
- Modern fixtures and calibration minimize variation so every cable matches operator specs.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with disciplined test flows.
Fiber Selection & Brand Options
We match fiber ribbon line to minimum bend radius, attenuation, and install environment. 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 satisfy sourcing standards.
Strength member integration
Strength members use dielectric FRP or galvanized steel wire. FRP is preferred where non-conductive runs are required. Steel wire adds tensile strength for long-span aerial runs and grounding needs.
Jacket Options and Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility and ease of handling, and PE for outdoor UV and moisture resistance. Closed-loop control of temperature and capstan ratios stabilizes line speed and dimensional tolerances.
| Component | Dielectric FRP | Metallic Steel |
|---|---|---|
| Use case | Non-conductive runs | High-tension aerial runs |
| Key benefit | Lightweight, inert | High strength |
| Installation note | Easier terminations | Bonding/grounding required |
Testing & Verification
Inline geometry/concentricity checks operate in-line. Final optical tests confirm attenuation and reflectance. Each order includes a full test report and lab results from high-temperature, 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. Lot records and FAI approvals provide traceability and compliance for U.S. projects.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment provides a focused portfolio of FTTH drop designs that suit both 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/ducts. It keeps bend loss low for easy routing in MDU corridors and hallways.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs include a messenger element to carry tensile loads. Choose FRP (dielectric) for electrical isolation or steel messenger when bonding/grounding and higher tensile strength are required.
Strength member and core layouts
We provide both dielectric and metallic strength member configurations to match safety and EMI rules. Center loose tube and unitube flat types balance crush resistance and Fiber draw tower for fast terminations.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor durability. Each series is validated for mechanical and optical quality before shipment.
| Type | Application | Strength element | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | FRP (dielectric) | LSZH |
| Self-supporting (aerial) | Overhead spans | Steel wire or FRP | Polyethylene |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Unitube flat | Low count, quick strip | FRP or steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for patch cord prep.
Our production line uses 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 real-world speeds near 20 terminal operations per minute.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH/PVC jackets and trims FRP or steel strength members to precise reserved lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and minimize downtime.
PLC & Photoelectric for Precision
PLC logic + photoelectric sensors deliver precise positioning and feedback control. Inline checks feed control charts so operators can adjust drifts before out-of-control conditions occur.
| Feature | Spec | Benefit |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Actuation | Cylinder-based | 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 loading maintain clean workcells.
- Process control plans capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without compromising accuracy.
CLX-BPO2 Capabilities on Our Line
The CLX-BPO2 provides industrial-grade strip/trim to our line, cutting cycle time while maintaining consistent prep.
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, yielding about 20 terminal preparations 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 translates 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 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 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-triggered start cut idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass ease integration into workcells.
- Cylinder-driven motion and closed-loop control improve line reliability and lower maintenance interruptions.
| Specification | Value | Benefit |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5 to 35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0 to 11.0 mm | Meets strength and termination needs |
| Power & size | 110–220V, 50W; 40×18×18 cm | Easy integration into existing equipment |
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.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures each build to fit your network requirements and simplify deployment. We pair concise options with predictable manufacturing windows so your teams get install-ready reels.
Choose 1–4 core designs with single-mode or multimode fiber. Options include OS1/OS2 plus OM2–OM4 along with G.652D and G.657 variants to align with optics and connector plans.
We Pantone-match sheath colors for quick field identification and consistent asset tags.
Jacket materials, print legends, and branding
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 tailored reels and packaging to suit storage and handling. Choose flat bow-type or self-supporting and steel wire or FRP strength members to meet span and isolation needs.
| Option | Typical | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and reels |
| Sheath | LSZH, PE, PVC | Indoor/Outdoor fit |
| Design | 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 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 high-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials and 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 QC gates stop nonconforming items before they leave the factory.
Traceability 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 accelerate approvals and receiving inspection.
- Line checks and final inspection reduce field failures and lower warranty events.
- QA packages include spec confirmation and formatted test data for quick review.
- Ongoing trend analysis drive preventive maintenance and raise long-term reliability.
| Test | Purpose | Result |
|---|---|---|
| Heat exposure | Thermal stability | Validated heat endurance |
| Salt spray | Corrosion robustness | Qualified for outdoor use |
| Vibration | Mechanical robustness | Reduced field failures |
FTTH Drop Cable Pricing & Cost Drivers
Budget planning for a drop starts with fiber and jacket choices and is shaped by volume and customization.
Typical prices vary widely—from about $30–$1,000 per unit—based on fiber grade, jacket material, reel 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 structures and steel strength elements increase material/labor. Custom colors, logos, and print legends add setup time and impact pricing on small runs.
Order length, volume, and customization impact on price
Longer put-ups and larger volumes lower unit cost. Small quantities often include setup charges and higher per-unit charges.
- Changeovers and special cutters increase lead time and add cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets across phases.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Optical grade | Large | Right-size spec to budget |
| Jacket type | Medium | Evaluate LSZH vs PE |
| Order length / volume | Large | Consolidate runs to cut unit cost |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align staffing and sites. Predictable windows reduce downtime and help control cost when a rollout is underway.
Scheduling & 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 provides updates/tracking so installation teams know when reels arrive. For tight schedules, we hold contingency capacity to pull in critical-path orders.
Why MOQ 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 put-ups and staging to choose reel sizes that cut waste and handling. Staggered batches can balance inventory holding with frequent, smaller deliveries to job sites.
Installation Scenarios & Readiness
On-site conditions determine whether a self-supporting aerial, duct pull, or direct burial is the right choice 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 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 require proper depth control per local codes and moisture barriers to protect the optic core over time.
Indoor Distribution and ONT
Indoor riser and plenum routes favor LSZH jackets 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 risk, and hardware fit. Standardized line prep shortens install time and minimizes scrap.
| Deployment | Key feature | Installer note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Underground duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct-buried | PE with moisture barrier | Follow local depth and warning tape rules |
| Interior | LSZH with tight-bend support | Maintain bend radius at penetrations |
Our approach delivers a consistent installation across indoor outdoor transitions. That leads to fewer callbacks, speeds 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.
- 24/7 availability for status updates and technical guidance.
- Warranty includes free replacement for confirmed quality issues.
- Schedule coordination for urgent changes or acceleration requests.
- Config control so shipped items match agreed specs consistently.
| Area | Scope | Outcome |
|---|---|---|
| Engineering | Specs + pilots | Reduced field issues |
| Testing | Lab trials & 100% test reports | Traceable quality |
| After-sales | Rapid replacement & root-cause | Lower downtime |
Wrap-Up
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
We deliver customized FTTH drop solutions 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-enabled prep machines, reduces variability and shortens turnaround. Our equipment and machines 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 extend service life. Dedicated support guides scheduling, logistics, and after-sales care so your deployment remains on plan.
Contact Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every fiber optic and optic cable shipment with lab validation and responsive service.
