FTTH Cable Production: Step-by-Step Manufacturing Process
Did you know: more than 70% of U.S. broadband rollouts now depend on fiber networks that demand tight manufacturing control to hit performance targets.
Shanghai Weiye OFC Equipment runs complete FTTH cable production line manufacturing, from selecting brand fibers like Fujikura or Corning® SMF-28e to final test reports that ensure 100% quality assurance.
Our drop designs fit overhead, ducted, and direct burial installation, with low-smoke zero-halogen (LSZH), PVC, and PE jacket options and arrangements from 1 to 4 cores. We supply OS1/OS2 and OM2–OM4 grades plus G.652D and G.657 variants, Pantone-matched sheath colors, and logo printing.
Automated machines and high-precision equipment stabilize line speed and maximize repeatability. Typical lead times are 4–5 days for orders under 100 km and 7–10 days for < 500 km, with an min. order of 1 km and warranty covering free replacement for confirmed quality issues.
Continue to learn how our materials, tests, and support combine to lower lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment provides complete production and laboratory testing for U.S. deployments.
- A range of jacket options and optical grades cover different install environments.
- Automated lines and machines deliver consistent quality and reliable optical performance.
- Fast lead times, low MOQ, and brand fiber options keep procurement predictable.
- Complete reports and after-sales warranty back product reliability and compliance documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment delivers tailored drop solutions with complete test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment combines purpose-built equipment with stringent material control. We offer customized service and products for residential/MDU deployments. Every order includes 100% quality assurance and complete test reports.
Our lab performs high heat, salt spray, and vibration tests to validate durability. Jacket options cover LSZH, PVC, and PE. Designs offer flat bow-type and figure-8/self-supporting styles and support brand fibers such as Fujikura® and Corning SMF-28e.
- Documented line control and in-process checks for auditable shipments.
- Technical support for specification reviews, trials, and volume ramp.
- Modern fixtures and calibration minimize variation so every cable meets carrier standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, pairing brand fiber choices with disciplined test flows.
Fiber Selection & Brand Options
We match fiber secondary coating line to bend radius, loss, and deployment type. 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.
Integrating Strength Members
Strength members employ dielectric FRP or metallic steel wire. FRP is preferred where non-conductive runs are required. Steel wire provides tensile strength for long-span aerial runs and grounding needs.
Jacket extrusion and 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 stabilizes line speed and critical dimensions.
| Member | Dielectric FRP | Steel wire |
|---|---|---|
| Use case | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Light, non-corrosive | High strength |
| Installer note | Easier terminations | Bonding/grounding required |
Testing & Verification
Inline geometry and concentricity checks run during manufacturing. Final optical tests verify loss and reflectance. Each order ships with a full test report and lab results from high heat, salt fog, and vibration tests to confirm handling for drop terminations and field use.
Typical lead times are 4–5 days for < 100 km and 7–10 days for < 500 km. Material lot records and first-article approvals provide 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 suit both tight indoor routes and exposed aerial spans. Each option combines tested materials with field-termination geometry and consistent 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 designs for aerial spans
Self-supporting FTTH drop designs use a messenger element to handle tension. Choose FRP (dielectric) for non-conductive runs 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. Central loose-tube and unitube flat types balance crush resistance and compact fiber unit for quick termination.
Jackets for Indoor/Outdoor
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 | Application | Strength element | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | Dielectric FRP | LSZH |
| Self-supporting (aerial) | Overhead spans | Steel wire or FRP | Polyethylene |
| Central loose-tube | Higher fiber counts | FRP | LSZH/PE |
| Flat unitube | Low-count, easy strip | FRP or steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment reduce manual handling and boost throughput for drop patch preparation.
Our production line integrates automated machines that cut/strip drop cords to raise throughput and cut labor variability.
The CLX-BPO2 automated stripper uses PLC + 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 reserved lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and minimize downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors give exact positioning and closed-loop control. Inline checks feed control charts so operators can adjust drifts before out-of-control conditions occur.
| Item | Spec | Benefit |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | High throughput |
| Drive | 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 feeders keep the line clean.
- PCPs document calibration and key parameters.
- Integrated assets and trained operators 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, reducing cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output and standardize prep quality. The unit cycles in ~1.5 seconds, producing around 20 preps per minute in production.
PLC/photoelectric control deliver exact 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 ~1.5 seconds per cycle. This enables 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 fit 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 maintain precision.
- Automatic waste ejection and sensor start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg weight simplify cell integration.
- Cylinder-driven motion and PLC/photoelectric control boost reliability and lower maintenance interruptions.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5–35.0 mm | Fits common connector processes |
| 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 helps our production lines meet volume goals without compromising quality.
Custom Specs for 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 get install-ready reels.
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 match your optics and connector plans.
We match sheath colors to Pantone codes for fast field ID and consistent asset tagging.
Branding and Print Options
Select LSZH/PVC/PE jackets based on route and safety rules. Custom print legends and logos support inventory and warranty tracking.
Length options, packaging, and special structures
Standard put-ups are 1 km, 2 km, and 4 km with custom 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.
| Choice | Typical | Advantage |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Simpler staging and reels |
| Sheath | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Structure | Flat bow / 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.
Environmental and Mechanical Tests
Our lab conducts elevated-temperature exposure, salt fog corrosion, and vibration tests to qualify materials/assemblies. These tests simulate 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 QC gates prevent nonconforming shipments before they leave the factory.
Traceability & Compliance
Batch records tie test data to reels and serials so audits and warranty claims are simple to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- Line checks and final inspection reduce field failures and lower warranty events.
- QA packages include spec confirmation and formatted test data for rapid review.
- Ongoing trend analysis inform preventive maintenance and improve long-term reliability.
| Test | Why | Outcome |
|---|---|---|
| Heat exposure | Material stability | Validated heat endurance |
| Salt-fog | Corrosion robustness | Outdoor suitability |
| Mechanical vibration | Resistance to vibration | Reduced field failures |
Cost Drivers and Pricing
Budgeting for a drop run 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 (G.652/G.657/OM2–OM4), jacket chemistry (LSZH, PVC, PE), length, and structural design.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber grade, sheath material, and the structural type chosen for deployment.
Self-supporting structures and steel strength elements raise material and labor input. Custom sheath colors/logos/legends add setup and influence price for short runs.
Length/Volume/Customization Impact
Longer put-ups and larger volumes lower unit cost. Short runs often carry setup fees and higher per-unit charges.
- Changeovers and special cutters 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 | Price impact | Recommendation |
|---|---|---|
| Optical grade | Large | Right-size spec to budget |
| Jacket type | Medium | Compare LSZH vs. PE for total cost |
| 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 reduce downtime and control costs 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 schedule line 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 pull in critical-path orders.
Minimum order quantity and why it matters
The MOQ is 1 km. This reflects line setup such as wire/die adjustments that consume start-up material and scrap.
We review your put-ups and staging to select reels to reduce waste/handling. Batch releases can balance inventory with more frequent small-site deliveries.
Installation readiness and application scenarios
On-site conditions dictate whether a self-supporting aerial, ducted pull, or direct-buried run is the right choice for a project.
Deployment Considerations
For aerial runs, Shanghai Weiye OFC Equipment advises self-supporting designs with correct strength members to manage sag/tension for long-term reliability.
Duct installations work best with low-friction jackets and crush-resistant constructs so pulling does not damage fibers. 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 barriers to protect the optic core over time.
Indoor riser/plenum distribution and ONT termination
Indoor riser/plenum routes prefer LSZH to meet smoke/flame codes. Flat drop cable forms 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 fit. Standardized prep from the production line shortens install time and minimizes scrap.
| Scenario | Key feature | Installer note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Underground duct | Low-friction, crush-resistant | Use pull tape and proper lubricant |
| Direct burial | PE with moisture barrier | Follow depth/warning tape codes |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at wall penetrations |
Our approach delivers a consistent installation across indoor outdoor transitions. That reduces callbacks, faster activations, and stable field performance for your system.
Support from Spec to Service
Our team coordinates tests, line schedules, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements capture through approved drawings and pre-production builds. We deliver documentation templates and clear installation notes so field crews work from the same plan.
After-sales service includes fast response, RCA, and corrective action. All products ship with full reports and traceability to support QA acceptance.
- Round-the-clock availability for status and technical support.
- Warranty includes free replacement for confirmed quality issues.
- Schedule coordination for expedites and urgent changes.
- Config control so shipped items match agreed specs consistently.
| Area | Scope | Benefit |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| Testing | Lab trials & 100% test reports | Full traceability |
| After-sales | Fast replace + RCA | Minimized downtime |
Conclusion
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-enabled prep machines, reduces 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 specs, timeline, and volume. We stand behind every shipment with laboratory validation and responsive service.