FTTH Cable Production: How the Manufacturing Process Works
Surprising fact: more than 70% of new U.S. broadband builds now use fiber networks that require precise manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment handles full-cycle FTTH cable production line manufacturing, from selecting brand fibers like Fujikura® or Corning SMF-28e to complete test reports that ensure 100% quality assurance.
Our drop designs fit overhead, ducted, and direct burial installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and PE jacket options and arrangements from 1–4 cores. We offer single-mode OS1/OS2 and multimode OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and logo printing.
Automation and high-precision equipment stabilize line speed and repeatability high. Typical lead times run four to five days for orders under 100 km and seven to ten days for < 500 km, with an MOQ of 1 km and warranty for free replacement on quality issues.
Keep reading to learn how our materials, tests, and support help reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment offers complete production and laboratory testing for U.S. deployments.
- Multiple jacket choices and fiber grades support varied installation environments.
- Automated production lines provide stable quality and reliable optical performance.
- Quick lead times, low minimums, and brand fiber options help plan procurement reliably.
- Comprehensive test reports and warranty support product reliability and documentation needs.
Expert FTTH manufacturing 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 dedicated manufacturer, Shanghai Weiye OFC Equipment combines purpose-built equipment with tight material control. We offer custom builds and services for single-family and MDU rollouts. Every order comes with full QA coverage and full test reports.
Our lab performs high-temperature, salt spray, and vibration testing to verify durability. Jacket options include LSZH, PVC, and PE. Designs cover bow-type flat and figure-8/self-supporting styles and support brand fibers such as Fujikura and Corning SMF-28e.
- Controlled production lines and in-process checks for auditable shipments.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixturing and calibration reduce variability so every cable meets carrier standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with disciplined test flows.
Optical fiber selection and brand options
We match FTTH cable production line to minimum bend radius, loss, 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 available to meet procurement standards.
Integrating Strength Members
Strength members use dielectric FRP or galvanized steel wire. FRP is ideal where non-conductivity is necessary. Steel wire provides tensile strength for longer aerial spans and bonding/grounding needs.
Jacket extrusion and process 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 extruder temperature and capstan speed keeps line speed stable and critical dimensions.
| Component | FRP | Metallic Steel |
|---|---|---|
| Use case | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Light, non-corrosive | Very high tensile strength |
| Installer note | Easier terminations | Bonding/grounding required |
In-Process and Final Testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests verify attenuation and return loss. Each order includes a full test report and lab results from high-temperature, salt fog, and vibration tests 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. 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 provides a compact 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 consistent optical performance.
The bow-type flat drop cable keeps a small footprint for risers/ducts. It keeps bend loss low for easy routing in hallways and MDUs.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs use a support messenger to carry tensile loads. Choose dielectric FRP for non-conductive runs or steel wire when bonding/grounding and extra tensile strength are required.
Layouts & Strength Members
We offer both dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and flat unitube types balance crush resistance and Fiber draw tower for quick termination.
Indoor/outdoor jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor UV and moisture resilience. Each family is validated for mechanical/optical performance before shipment.
| Type | Application | Strength member | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting | Aerial spans | Steel wire or FRP | Polyethylene |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH or PE |
| Unitube flat | Low count, quick strip | FRP or steel | LSZH or PE |
Production line equipment that ensures quality and speed
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 raise throughput 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.
Auto Cut & Strip Capabilities
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 control for precision and repeatability
PLC logic and photoelectric sensors give exact positioning and feedback control. Inline checks feed control charts so operators can adjust drifts before defects grow.
| Feature | Spec | Benefit |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Actuation | Pneumatic cylinders | High speed and reliability |
| Materials | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Process control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Automated waste 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 sacrificing accuracy.
What the CLX-BPO2 Adds
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 increase throughput and standardize terminal quality. The unit cycles in ~1.5 seconds, producing around 20 preps per minute in production.
PLC/photoelectric control enable precise detection and repeatable actuation. 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 normal production conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable jacket strip length from 17.5–35.0 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 cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Custom tooling are offered for nonstandard sizes to preserve precision.
- Auto-eject scrap and sensor-triggered start cut idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass ease integration into workcells.
- Pneumatic cylinders and PLC/photoelectric control boost reliability and lower maintenance interruptions.
| Specification | Rating | Benefit |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5–35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0–11.0 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 prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 supports our lines in meeting volume targets without compromising quality.
Custom Specs for Your FTTH System
Shanghai Weiye OFC Equipment configures each build to meet your network requirements and simplify deployment. 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 and G.657 variants to match your optics and connector plans.
We Pantone-match sheath colors for fast field ID 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.
Lengths, Packaging & Special Builds
Standard reel lengths are 1/2/4 km with custom reels and packaging to fit storage/handling. Choose flat bow-type or self-supporting and steel wire or FRP strength members to fit span and isolation requirements.
| Option | Typical | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Less staging, easier reels |
| Jacket | LSZH / PE / PVC | Indoor/Outdoor fit |
| Design | Bow-type / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and provides docs that lists final specifications for easy on-site QA.
Quality assurance, testing, and documentation
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item has recorded acceptance data at ship.
Lab Testing: Heat, Salt Spray & Vibration
Our lab conducts elevated-temperature exposure, salt fog corrosion, and mechanical vibration 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 logs attenuation, return loss, and geometry where applicable. Final inspection gates stop nonconforming items before they leave the factory.
Traceability & Compliance
Lot/batch records link tests to reels/serials so audits and claims are easy to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection prevent field failures and lower warranty events.
- QA packages include spec confirmation and formatted data for rapid review.
- Continuous test trends drive preventive maintenance and raise long-term reliability.
| Trial | Purpose | Result |
|---|---|---|
| Heat exposure | Material stability | Pass at target temperature |
| Salt spray | Corrosion robustness | Qualified for outdoor use |
| Mechanical vibration | Resistance to vibration | Reduced field failures |
Pricing and cost drivers for FTTH drop cable
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, length, and structural design.
Materials, Grade, Jacket & 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 raise material and labor input. 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 unit prices.
- Changeovers and special cutters extend lead time and add to cost.
- Clear RFQs with schedule alignment let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets across phases.
| Factor | Price impact | Guidance |
|---|---|---|
| Optical grade | High impact | Balance spec vs. budget |
| Jacket type | Medium | Evaluate LSZH vs PE |
| Length/Volume | High impact | 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.
Scheduling & 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 maintain on-time delivery.
The service team provides updates/tracking so installation teams can plan arrivals. For tight schedules, we hold contingency capacity to accelerate critical-path orders.
Minimum order quantity and why it matters
The MOQ is 1 km. This reflects setup needs 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. Staggered batches can balance inventory with frequent, smaller deliveries to job sites.
Installation Scenarios & Readiness
On-site conditions determine whether a self-supporting aerial, duct 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 control sag and tension for long-term reliability.
Duct installations perform best with low-friction jackets and crush-resistant builds 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 prefer LSZH to meet flame and smoke rules. Flat drop profiles strip clean and present controlled strength stubs for quick ONT termination.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware fit. Standardized line prep shortens install time and reduces scrap.
| Scenario | Key design | Field note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Underground duct | Low-friction, crush-resistant | Use pull tape and proper lubricant |
| Direct burial | PE jacket, 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 reduces callbacks, faster activations, and stable field performance for your system.
Comprehensive Support & After-Sales
Our team coordinates tests, line schedules, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements through approved drawings and pilot builds. We deliver documentation templates and clear install 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.
- 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.
- Configuration control so shipped items match agreed requirements every time.
| Area | Scope | Benefit |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Fewer field issues |
| QA/Testing | Lab + 100% reports | Full traceability |
| After-sales | 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 pair material choices with validated manufacturing and lab testing. Every reel ships with a 100% test report and documented lab trials to support U.S. field acceptance.
A hardened production line, including CLX-BPO2-enabled prep machines, cuts variability and shortens turnaround. Our equipment set standardize strip/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 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 shipment with lab validation and responsive service.