FTTH Cable Production: How the Manufacturing Process Works
Quick fact: more than 70% of new broadband deployments in the U.S. now rely on fiber networks that require precise manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment manages end-to-end compact fiber unit manufacturing, from selecting brand fibers like Fujikura or Corning SMF-28e to final test reports that deliver 100% QA.
Our FTTH drop designs fit aerial, underground, and direct burial installation, with LSZH, polyvinyl chloride (PVC), and polyethylene (PE) jacket options and arrangements from 1–4 cores. We supply single-mode OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone sheath colors, and logo printing.
Automated machines and precision equipment keep line speed steady and keep repeatability high. Typical lead times run four to five days for orders < 100 km and seven to ten days for < 500 km, with an min. order of 1 km and warranty for free replacement on quality issues.
Read on to see how materials, testing, and support combine to lower lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment offers end-to-end manufacturing and lab testing for United States projects.
- A range of jacket options and fiber grades fit different install environments.
- Automated production lines ensure stable quality and stable optical performance.
- Quick lead times, low minimums, and recognized brand fibers support reliable procurement planning.
- Comprehensive test reports and warranty support product reliability and documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment delivers customized drop cables with full test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment combines specialized equipment with stringent material control. We provide custom builds and services for single-family and MDU rollouts. Every order comes with full QA coverage and complete test reports.
Our lab runs high heat, salt spray, and vibration tests to validate durability. Jacket options include LSZH, PVC, and PE. Designs offer flat bow-type and self-supporting styles and support brand fibers such as Fujikura® and Corning SMF-28e.
- Documented line control and production checks for shipments with audit trails.
- Technical support for specs, trials, and ramp to volume.
- Modern fixturing and calibration minimize variation so every cable meets carrier standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are built around network requirements, pairing brand fiber choices with disciplined test flows.
Optical fiber selection and brand options
We align FTTH cable production line to minimum bend radius, loss, and deployment type. 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.
Strength Member Options
Strength members employ dielectric FRP or metallic steel wire. FRP is ideal where non-conductive runs are required. Steel wire provides 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. Tight process control of temperature and capstan ratios stabilizes line speed and critical dimensions.
| Member | Dielectric FRP | Steel wire |
|---|---|---|
| Use case | Electrical isolation | High-tension aerial runs |
| Advantage | Light, non-corrosive | High strength |
| Installation note | Simple terminations | Bonding/grounding required |
Inline and final testing
Inline geometry/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 heat, salt-spray, and vibration tests to confirm handling for drop terminations and field use.
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 provide traceability and compliance for U.S. programs.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment provides 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 keeps bend loss low for easy routing in MDU corridors and hallways.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs use a messenger element to handle tension. Choose FRP (dielectric) for non-conductive runs or steel messenger when bonding and extra tensile strength are required.
Strength member and core layouts
We offer dielectric and metallic strength member configurations to match safety and EMI rules. Center loose tube and flat unitube types balance crush resistance and fiber secondary coating line 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.
| Design | Application | Strength member | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | FRP (dielectric) | LSZH |
| Self-supporting (aerial) | Aerial spans | Steel wire or FRP | Polyethylene |
| Central loose-tube | Higher-count builds | FRP | LSZH or PE |
| Flat unitube | Low-count, easy strip | FRP or steel | LSZH/PE |
Production Assets for Speed and Quality
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for drop patch preparation.
Our production line integrates automated machines that cut/strip drop cords to increase output and reduce operator variability.
The CLX-BPO2 auto-stripping machine uses PLC + 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 stub lengths. Pneumatic cylinder actuators provide quick, repeatable motion and low downtime.
PLC & Photoelectric for Precision
PLC logic and photoelectric sensors deliver precise positioning and feedback control. Inline checks feed control charts so operators can correct trends before defects grow.
| Feature | Capability | Result |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | High throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic loading maintain clean workcells.
- PCPs document calibration and key parameters.
- Integrated assets and trained operators help meet FTTH volume goals without compromising accuracy.
What the CLX-BPO2 Adds
The CLX-BPO2 provides industrial-grade strip/trim to our line, reducing cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to increase throughput and standardize terminal quality. The unit runs at an approximate cycle time of 1.5 seconds, producing around 20 preps per minute in production.
PLC/photoelectric control deliver exact detection and repeatable actuation. That control keeps strip and stub lengths within tight tolerances.
Cycle time and throughput
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 17.5–35.0 mm. Reserved strength member stubs are set between 7.0 and 11.0 mm to match 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 offered for non-standard cross-sections to maintain precision.
- Auto-eject scrap and sensor-triggered start cut idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass simplify cell integration.
- Pneumatic cylinders and closed-loop control improve line reliability and reduce maintenance downtime.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5–35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0–11.0 mm | Supports termination strength |
| 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 get drop parts install-ready. The CLX-BPO2 helps our production lines meet volume goals without compromising quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures each build to fit your network requirements and simplify field rollout. We combine focused options with predictable schedules so your teams receive ready-to-install products.
Choose 1 to 4 cores with single-mode or multimode fiber. Options include OS1/OS2 plus OM2–OM4 plus G.652D and G.657 variants to match your optics and connector plans.
We match sheath colors to Pantone codes for quick field identification and consistent asset tagging.
Jackets, Legends & Branding
Select LSZH, PVC, or PE jackets to suit route and safety requirements. 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 suit storage and handling. Choose flat bow-type or self-supporting and FRP or steel members to fit span and isolation requirements.
| Choice | Common choice | Benefit |
|---|---|---|
| Length | 1, 2, or 4 km | Less staging, easier reels |
| Jacket | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Structure | Flat bow / Self-supporting | Routing and span flexibility |
As a supplier, 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 ships with recorded acceptance data.
High-temperature, salt spray, and vibration laboratory testing
Our lab conducts elevated-temperature exposure, salt fog corrosion, and vibration tests to qualify materials/assemblies. These tests recreate field stresses for indoor/outdoor applications.
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 QC 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 follows common customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection reduce field failures and cut warranty events.
- QA packages include spec confirmation and formatted test data for rapid review.
- Ongoing trend analysis drive preventive maintenance and improve long-term reliability.
| Trial | Why | Outcome |
|---|---|---|
| High-temperature | Material stability | Pass at target temperature |
| Salt spray | Corrosion resistance | Qualified for outdoor use |
| Vibration | Resistance to vibration | Improved field reliability |
Cost Drivers and Pricing
Budget planning for a drop starts with fiber and jacket choices and is refined 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.
Primary Cost Inputs
The primary cost drivers are fiber grade, sheath material, and the structural type chosen for deployment.
Self-supporting structures and steel members increase material/labor. Custom sheath colors/logos/legends add setup time and impact pricing on small runs.
Length/Volume/Customization Impact
Longer reels and higher volume orders lower unit cost. Small quantities often carry setup fees and higher unit prices.
- Line changeovers and custom tooling extend lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets across phases.
| Driver | Price impact | Recommendation |
|---|---|---|
| Fiber grade | High impact | Balance spec vs. budget |
| Sheath material | 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 crews and sites. Predictable windows cut 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 orders under 500 km. We schedule line capacity to match your rollout milestones and to keep deliveries on time.
The service team provides updates/tracking so installation teams can plan arrivals. For compressed schedules, we reserve contingency capacity to pull in critical-path orders.
MOQ and Rationale
The MOQ is one kilometer. This reflects setup needs such as wire/die adjustments that consume start-up material and scrap.
We review your length and staging plans to select reels to reduce waste/handling. Batch releases can balance inventory with frequent, smaller deliveries to job sites.
Where and How to Deploy
Site conditions determine whether a self-supporting aerial, duct 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 control sag and 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 is needed.
Direct-buried designs need correct burial depth per local codes and moisture-resistant jackets to protect the optic core over time.
Indoor Riser/Plenum & ONT
Indoor riser and plenum routes favor LSZH jackets 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 needs, lightning exposure, and hardware compatibility. Standardized prep from the production line shortens install time and reduces scrap.
| Deployment | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Duct | Low-friction jacket, crush resistance | Use pull tape + lubricant |
| Direct burial | PE jacket, moisture barrier | Follow depth/warning tape codes |
| Interior | LSZH with tight-bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor/outdoor transitions. That leads to fewer 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 offers engineering support from early requirements through approved drawings and pilot builds. We deliver documentation templates and clear installation notes so field crews share a unified 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 updates and technical guidance.
- 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.
| Support area | Scope | Benefit |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| Testing | Lab trials & 100% test reports | Traceable quality |
| Service | Fast replace + RCA | Minimized downtime |
Conclusion
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
We deliver customized FTTH drop solutions that combine materials with validated manufacturing and lab tests. Every reel ships with a 100% test report and documented trials to support field acceptance in the United States.
A robust production line, including CLX-BPO2 prep assets, cuts variability and speeds 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 performance and cost to extend service life. Dedicated support guides scheduling, logistics, and after-sales care so your deployment remains on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every shipment with laboratory validation and responsive support.
