Fiber-to-the-Home Cable Production: Manufacturing Process Explained
Surprising fact: in excess of 70% of new broadband deployments in the U.S. now use fiber networks that require tight manufacturing control to meet performance goals.
Shanghai Weiye OFC Equipment manages full-cycle compact fiber unit manufacturing, from sourcing brand fibers like Fujikura or Corning® SMF-28e to complete test reports that ensure 100% quality assurance.
Our drop designs suit aerial, ducted, and direct burial installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and polyethylene (PE) jacket options and configurations from 1–4 cores. We provide OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and logo printing.
Automation and high-precision equipment keep line speed steady and keep repeatability high. Typical lead times run four to five days for orders < 100 km and 7–10 days for < 500 km, with an MOQ of 1 km and warranty for free replacement on quality issues.
Continue to understand how our materials, tests, and support combine to lower 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 optical grades cover different install environments.
- Automated production lines deliver consistent quality and reliable optical performance.
- Quick lead times, low MOQ, and recognized brand fibers keep procurement predictable.
- Comprehensive test reports and warranty back product reliability and documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment delivers customized drop cables 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 residential/MDU deployments. Every order includes 100% quality assurance and complete test reports.
Our lab conducts high heat, salt-fog, and vibration testing to verify durability. Jacket options include LSZH, PVC, and PE. Designs include 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 auditable shipments.
- Technical support for specification reviews, trials, and volume ramp.
- Modern fixtures 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 strict test routines.
Optical fiber selection and brand options
We select fiber secondary coating line to bend radius, attenuation, 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 meet procurement standards.
Strength Member Options
Strength members employ dielectric FRP or metallic steel wire. FRP is ideal where non-conductivity is necessary. Steel wire provides tensile strength for long-span aerial runs and grounding needs.
Extrusion & Process Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility, and PE for outdoor UV and moisture resistance. Tight process control of extruder temperature and capstan speed keeps line speed stable and critical dimensions.
| Component | Dielectric FRP | Steel wire |
|---|---|---|
| Primary use | Electrical isolation | Aerial spans, high tensile |
| Advantage | Light, non-corrosive | High strength |
| Installation note | Simple terminations | Bonding/grounding required |
Inline and final testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests verify attenuation and reflectance. Each order ships with 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 4–5 days for < 100 km and under 500 km in 7–10 days. Material lot records and first-article approvals support traceability and compliance for U.S. projects.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment offers a focused portfolio of FTTH 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 keeps a small footprint for risers/ducts. It keeps bend loss low for simple routing in MDU corridors and hallways.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs use a messenger element to carry tensile loads. Choose FRP (dielectric) for non-conductive runs or steel wire when bonding and extra tensile strength are required.
Layouts & Strength Members
We offer dielectric and metallic strength member configurations to meet safety/EMI requirements. Central 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 indoor flame/smoke compliance and PE for outdoor durability. Each series is qualified for mechanical and optical quality before shipment.
| Design | Best use | Strength element | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | Dielectric FRP | LSZH |
| Self-supporting | Overhead spans | FRP/Steel | Polyethylene |
| Central loose-tube | Higher-count builds | FRP | LSZH/PE |
| Flat unitube | Low-count, easy strip | FRP/Steel | LSZH/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 integrates automated machines that cut/strip drop cords to raise throughput and cut labor variability.
The CLX-BPO2 auto-stripping machine uses PLC + 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/PVC jackets and trims FRP or steel strength members to precise reserved lengths. Cylinder-driven actuators deliver fast, repeatable motion and low downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors give exact positioning and closed-loop control. Inline checks update SPC charts so operators can correct trends before out-of-control conditions occur.
| Item | Spec | Benefit |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Cylinder-based | Fast/reliable motion |
| Materials | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Automated waste ejection and ergonomic feeders 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 maintaining consistent prep.
Shanghai Weiye OFC Equipment deploys the CLX-BPO2 to increase throughput and standardize terminal quality. The unit runs at an approximate cycle time of 1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC and photoelectric control deliver exact 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 converts to steady throughput under normal production conditions.
Supported jacket and reserved strength lengths
The CLX-BPO2 handles LSZH/PVC 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.
Handling FRP and steel wire strength members
The machine cleanly cuts FRP and steel wire strength elements while protecting adjacent fibers. Custom tooling are available for non-standard cross-sections to maintain precision.
- Auto-eject scrap and sensor-triggered start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass ease integration into workcells.
- Pneumatic cylinders and PLC/photoelectric control boost reliability and reduce maintenance downtime.
| Spec | Value | Benefit |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0–11.0 mm | Supports termination strength |
| Power & size | 110–220V, 50W; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 supports our lines in meeting volume targets without sacrificing quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures every order 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, and OM2–OM4 plus 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 tagging.
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 FRP or steel members to fit span and isolation requirements.
| Option | Typical | Advantage |
|---|---|---|
| Length | 1 / 2 / 4 km | Simpler staging and reels |
| Sheath | LSZH, PE, PVC | Indoor/Outdoor fit |
| Design | Flat bow / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye schedules runs to your plan and delivers documentation that lists final specifications for straightforward QA on site.
QA, Testing & Documentation
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/assemblies. These tests recreate field stresses for indoor and outdoor use.
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.
Audit Trail and Compliance
Lot/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.
- In-line checks plus final inspection reduce field failures and cut warranty events.
- Quality packages include spec confirmation and formatted data for quick review.
- Ongoing trend analysis drive preventive maintenance and improve long-term reliability.
| Test | Why | Outcome |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt spray | Corrosion resistance | Qualified for outdoor use |
| Vibration | Mechanical robustness | Reduced field failures |
Pricing and cost drivers for FTTH drop cable
Budgeting for a drop run starts with fiber and jacket choices and is shaped by volume and customization.
Typical prices range broadly—from about $30–$1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket material, reel length, and design structure.
Primary Cost Inputs
The primary cost drivers are fiber grade, sheath material, and the chosen structure for deployment.
Self-supporting structures and steel strength elements raise material and labor input. Custom sheath colors/logos/legends add setup time and influence price for short 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 unit prices.
- Changeovers and special cutters extend 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 | Guidance |
|---|---|---|
| Optical grade | Large | Balance spec vs. budget |
| Jacket type | Medium impact | Compare LSZH vs. PE for total cost |
| Order length / volume | High impact | Consolidate where possible |
Logistics for the U.S.
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews and sites. Predictable windows reduce downtime and control costs 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 track your milestones and to keep deliveries on time.
The service team provides updates/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 setup needs such as wire/die adjustments that use startup material and generate scrap.
We review your put-ups and staging to choose reel sizes that cut waste and handling. Batch releases can balance inventory with frequent, smaller deliveries to job sites.
Installation readiness and application scenarios
Site conditions determine whether a self-supporting aerial, ducted pull, or direct burial is the right choice for a project.
Deployment Considerations
For aerial runs, Shanghai Weiye OFC Equipment advises self-supporting designs with appropriate members to manage sag/tension for long-term stability.
Duct installations perform best with low-friction sheaths and crush-resistant builds 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-resistant jackets to protect the optic core over time.
Indoor Distribution and ONT
Indoor riser and plenum routes prefer LSZH to meet smoke/flame codes. Flat drop cable forms strip clean and present controlled strength stubs for quick ONT termination.
We advise on steel vs FRP (dielectric) strength members based on bonding requirements, lightning exposure, and hardware compatibility. Standardized line prep shortens install time and minimizes scrap.
| Deployment | Key feature | Field note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| 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 jacket, tight bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That reduces callbacks, speeds activations, and reliable field performance for your system.
End-to-end support and after-sales service
Our team coordinates testing, scheduling, 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 provide doc templates and clear installation notes so field crews work from the same 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 with free replacement if any quality problems are confirmed.
- Coordination of line schedules for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed requirements every time.
| Support area | Scope | Benefit |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Fewer field issues |
| Testing | Lab trials & 100% test reports | Traceable quality |
| Service | Rapid replacement & root-cause | Lower downtime |
Final Thoughts
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
We provide custom FTTH drops that combine materials with validated manufacturing and lab tests. Every reel includes 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 and machines standardize strip/stub lengths so installers see consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance design and cost to maximize service life. Dedicated customer support covers scheduling/logistics/after-sales so your deployment stays on plan.
Contact Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with laboratory validation and responsive support.