Fiber-to-the-Home Cable Production: How the Manufacturing Process Works
Surprising fact: in excess of seventy percent of new U.S. broadband builds now rely on fiber networks that demand precise manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment handles complete fiber secondary coating line manufacturing, from choosing brand fibers like Fujikura or Corning SMF-28e to complete test reports that deliver 100% QA.
Our drop designs fit aerial, underground, and direct-buried installation, with LSZH, polyvinyl chloride (PVC), and polyethylene (PE) jacket options and core counts from 1–4 cores. We supply single-mode OS1/OS2 and OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and logo printing.
Automation and precision equipment stabilize line speed and keep repeatability high. Typical lead times run four to five 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.
Continue to learn how materials plus testing and support help reduce lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment offers end-to-end manufacturing and lab testing for United States projects.
- A range of jacket options and fiber grades cover indoor/outdoor environments.
- Automated production lines deliver stable quality and reliable optical performance.
- Fast lead times, low MOQ, and recognized brand fibers help plan procurement reliably.
- Complete reports and warranty back product reliability and compliance documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment provides customized drop cables with complete test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment combines purpose-built equipment with tight material control. We provide customized service and products for residential/MDU deployments. Every order comes with full QA coverage and full test reports.
Our lab performs high heat, salt spray, and vibration tests to validate durability. Jacket options include LSZH, PVC, and PE. Designs offer flat bow-type and figure-8/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.
- Engineering support for specification reviews, trials, and volume ramp.
- Modern fixturing and calibration minimize variation so every cable meets carrier standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are built around network requirements, pairing brand fiber choices with disciplined test flows.
Fiber Selection & Brand Options
We select fiber ribbon line to minimum bend radius, attenuation, and install environment. Options include OS1, OS2, OM2–OM4 and ITU-T G.652D, G.657.A1/A2. Brand fibers such as Fujikura and Corning SMF-28e are available to satisfy sourcing standards.
Strength Member Options
Strength members employ FRP (dielectric) or metallic steel wire. FRP is preferred where non-conductive runs are required. Steel wire provides tensile strength for longer aerial spans and bonding/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. Tight process control of temperature and capstan ratios stabilizes line speed and critical dimensions.
| Member | FRP | Steel wire |
|---|---|---|
| Use case | Non-conductive runs | Aerial spans, high tensile |
| Advantage | Lightweight, inert | High strength |
| Installation note | Simple terminations | Bonding/grounding required |
Testing & Verification
Inline geometry and concentricity checks operate in-line. 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 4–5 days for < 100 km and 7–10 days for < 500 km. 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 offers a compact portfolio of drop designs that cover tight indoor routes and exposed aerial spans. Each option combines tested materials with field-termination geometry and stable optical performance.
The bow-type flat drop cable minimizes footprint for risers/ducts. It reduces bend loss for simple routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs include a messenger element to handle tension. Choose FRP (dielectric) for electrical isolation or steel wire when bonding/grounding and higher tensile strength are required.
Core Layouts and Strength Members
We provide both dielectric and metallic strength member configurations to meet safety/EMI requirements. Center loose tube and flat unitube types balance crush resistance and fiber ribbone line for fast terminations.
Indoor/outdoor jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each family is validated for mechanical/optical performance before shipment.
| Type | Best use | Strength member | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | Dielectric FRP | LSZH |
| Self-supporting | Overhead spans | Steel wire or FRP | Polyethylene |
| Center loose tube | Higher-count builds | FRP | LSZH/PE |
| Unitube flat | Low-count, easy strip | FRP or steel | LSZH/PE |
Equipment Ensuring Quality and Throughput
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and boost throughput for drop patch preparation.
Our production line uses automated machines that cut/strip drop cords to increase output and reduce operator variability.
The CLX-BPO2 auto-stripping machine runs under PLC and photoelectric control. One cycle is ~1.5 s, giving ~20 terminals per minute in production.
Automated Cut/Strip for Drop Cords
The equipment strips LSZH and PVC jackets and trims FRP or steel strength members to precise stub lengths. Pneumatic cylinder actuators provide quick, repeatable motion and low downtime.
Closed-Loop Control for Repeatability
PLC logic + photoelectric sensors deliver precise positioning and feedback control. Inline checks update SPC charts so operators can correct trends before defects grow.
| Item | Spec | Result |
|---|---|---|
| CLX-BPO2 | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Automated waste ejection and ergonomic loading keep the line clean.
- Process control plans capture calibration intervals and critical parameters.
- Integrated assets and trained operators support FTTH volume targets without compromising accuracy.
CLX-BPO2 Capabilities on Our Line
The CLX-BPO2 provides industrial-grade strip/trim to our line, reducing cycle time while maintaining consistent prep.
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, yielding about 20 terminal preparations per minute in production.
PLC and photoelectric control enable precise detection and repeatable motion. That control keeps strip and stub lengths within tight tolerances.
Cycle time and throughput
Typical operation speed is 1.5s per cycle. This converts to steady throughput under normal production conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable jacket strip length from 17.5–35.0 mm. Reserved strength member stubs are adjustable from 7.0–11.0 mm to match common termination hardware.
Cutting FRP/Steel Members
The machine cleanly cuts FRP and steel wire strength elements while protecting neighboring fibers. Custom tooling are offered for nonstandard sizes to preserve precision.
- Auto-eject scrap and sensor-triggered start cut idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight ease integration into workcells.
- Cylinder-driven motion and closed-loop control boost reliability and lower maintenance interruptions.
| Spec | Rating | Why it matters |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | Supports high-volume runs |
| Strip lengths (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0 to 11.0 mm | Meets strength and termination needs |
| Power & size | 110–220V, 50W; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes terminal prep so field teams get drop parts install-ready. The CLX-BPO2 supports our lines in meeting volume targets without sacrificing quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures each build to fit your network requirements and simplify field rollout. We pair concise options with predictable manufacturing windows so your teams get install-ready reels.
Choose 1–4 core designs with SM or MM fiber. Options include OS1/OS2 plus OM2–OM4 plus G.652D/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.
Jackets, Legends & Branding
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom legends/logos support inventory and warranty tracking.
Lengths, Packaging & Special Builds
Standard put-ups are 1/2/4 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.
| Choice | Common choice | Advantage |
|---|---|---|
| Reel length | 1, 2, or 4 km | Simpler staging and reels |
| Jacket | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Design | Bow-type / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and delivers documentation 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 ships with recorded acceptance data.
Lab Testing: Heat, Salt Spray & Vibration
Our lab conducts elevated-temperature exposure, salt fog corrosion, and vibration tests to qualify materials/assemblies. These tests simulate field stresses for indoor and outdoor use.
100% test reports for every cable
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
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 prevent field failures and lower warranty events.
- QA packages include specifications confirmation and formatted data for quick review.
- Ongoing trend analysis inform preventive maintenance and improve long-term reliability.
| Test | Why | Result |
|---|---|---|
| Heat exposure | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion resistance | Outdoor suitability |
| Mechanical vibration | Resistance to vibration | Improved field reliability |
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 range broadly—from about $30 to $1,000 per unit—based on fiber grade, jacket material, reel length, and structural design.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, sheath material, and the chosen structure for deployment.
Self-supporting designs and steel members raise material and labor input. Custom sheath colors/logos/legends add setup and influence price for short runs.
Order length, volume, and customization impact on price
Longer reels and higher volume orders lower unit cost. Small quantities often carry setup fees and higher per-unit charges.
- Changeovers and special cutters extend lead time and add cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets over phases.
| Driver | Effect on price | Guidance |
|---|---|---|
| Fiber grade | High impact | Balance spec vs. budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Order length / volume | Large | Consolidate runs to cut unit cost |
Logistics for the U.S.
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align staffing and sites. Predictable windows cut downtime and help control cost when a rollout is underway.
Production Windows & Capacity
Typical production windows run 4–5 days for orders under 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 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 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 holding with frequent, smaller deliveries to job sites.
Installation readiness and application scenarios
On-site conditions dictate whether a self-supporting span, ducted pull, or direct burial 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 appropriate members to manage sag/tension for long-term stability.
Duct installations perform best with low-friction sheaths and crush-resistant constructs so pulling avoids fiber damage. PE jackets are typical 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 and plenum routes favor LSZH jackets to meet smoke/flame codes. Flat drop profiles strip clean and present controlled strength stubs for fast ONT terminations.
We guide the choice of steel or FRP (dielectric) strength members based on bonding needs, lightning exposure, and hardware compatibility. Standardized line prep reduces install time and minimizes scrap.
| Scenario | Key design | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Underground duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct burial | PE jacket, moisture barrier | Follow depth/warning tape codes |
| 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, faster 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 capture through approved drawings and pre-production builds. We deliver documentation 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 with free replacement if any quality problems are confirmed.
- Coordination of line schedules for expedites and urgent changes.
- Config control so shipped items match agreed requirements every time.
| Area | What we do | Benefit |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Reduced field issues |
| QA/Testing | Lab trials & 100% test reports | Full traceability |
| After-sales | Fast replace + RCA | Lower downtime |
Wrap-Up
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
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 lab trials to support U.S. field acceptance.
A hardened production line, including CLX-BPO2 prep assets, reduces variability and shortens turnaround. Our equipment and machines 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 guides scheduling, logistics, and after-sales care so your deployment remains on plan.
Contact Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every fiber optic and optic cable shipment with laboratory validation and responsive service.