Fiber-to-the-Home Cable Production: Manufacturing Process Explained
Surprising fact: in excess of seventy percent of new broadband deployments in the U.S. now depend on fiber networks that need precise manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment manages complete fiber secondary coating line manufacturing, from choosing brand fibers like Fujikura or Corning® SMF-28e to complete test reports that ensure 100% quality assurance.
Our drop designs are built for aerial, underground, and direct-buried installation, with LSZH, PVC, and PE jacket options and configurations from 1–4 cores. We supply single-mode OS1/OS2 and multimode OM2–OM4 grades plus ITU-T G.652D and ITU-T G.657 variants, Pantone sheath colors, and logo printing.
Automation and precision equipment keep line speed steady and keep repeatability high. Typical lead times are 4–5 days for orders under 100 km and seven to ten days under 500 km, with an min. order of 1 km and warranty for free replacement on quality issues.
Keep reading to understand 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 end-to-end manufacturing and lab testing for United States projects.
- A range of jacket options and optical grades support different install environments.
- Automated lines and machines provide consistent quality and stable optical performance.
- Quick lead times, low minimums, and brand fiber options keep procurement predictable.
- Complete reports and warranty back product reliability and compliance documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment provides customized drop cables with full test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment pairs specialized equipment with tight material control. We provide customized service and products for single-family and MDU rollouts. Every order comes with full QA coverage and full test reports.
Our lab performs high heat, salt-fog, and vibration testing to validate durability. Jacket options include LSZH, PVC, and PE. Designs include flat bow-type and figure-8/self-supporting styles and use brand fibers such as Fujikura® and Corning SMF-28e.
- Documented line control and in-process checks for shipments with audit trails.
- Technical support for requirements, pilots, and scaling.
- Modern fixturing and calibration minimize variation so every cable meets operator standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with rigorous test routines.
Optical fiber selection and brand options
We align fiber secondary coating 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 offered to satisfy sourcing standards.
Strength Member Options
Strength members employ FRP (dielectric) or metallic steel wire. FRP is ideal where non-conductive runs are required. Steel wire provides tensile strength for longer aerial spans 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 UV/moisture resistance outdoors. Tight process control of temperature and capstan ratios stabilizes line speed and dimensional tolerances.
| Member | FRP | Metallic Steel |
|---|---|---|
| Use case | Electrical isolation | Aerial spans, high tensile |
| Advantage | Light, non-corrosive | Very high tensile strength |
| Installation note | Simple terminations | Bonding/grounding required |
Testing & Verification
Inline geometry and concentricity checks operate in-line. Final optical tests confirm loss and return loss. Each order includes a full test report and lab results from high heat, salt-spray, and vibration trials 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. projects.
Our FTTH Drop Cable Types and Structures
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 keeps a small footprint for risers and conduit. It reduces bend loss for simple routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
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 extra 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 fiber ribbone line for fast terminations.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor UV and moisture resilience. Each family is qualified for mechanical and optical quality before shipment.
| Design | Best use | Strength element | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | Dielectric FRP | LSZH |
| Self-supporting | Overhead spans | FRP/Steel | Polyethylene |
| Central loose-tube | Higher-count builds | Dielectric FRP | LSZH/PE |
| Unitube flat | Low-count, easy strip | FRP/Steel | LSZH/PE |
Production Assets for Speed and Quality
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment cut manual handling and boost throughput for drop patch preparation.
Our production line uses automated machines that cut/strip drop cords to raise throughput and reduce operator variability.
The CLX-BPO2 auto-stripping machine uses PLC + photoelectric control. One cycle is ~1.5 s, 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/steel members to precise stub lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and low downtime.
PLC & Photoelectric for Precision
PLC logic and photoelectric sensors give exact positioning and feedback control. Inline checks update SPC charts so operators can correct trends before defects grow.
| Feature | Spec | Result |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | High throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Material handling | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Process control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic loading keep the line clean.
- PCPs document calibration and key parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets without sacrificing accuracy.
CLX-BPO2 auto-stripping machine capabilities in our line
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, reducing cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to increase throughput and standardize prep 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.
Cycle time and throughput
Typical operation speed is ~1.5 seconds per cycle. This converts to steady throughput under continuous line conditions.
Supported jacket and reserved strength lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable jacket strip length from 17.5 to 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 neighboring fibers. Custom tooling are available for non-standard cross-sections to preserve precision.
- Auto-eject scrap and sensor start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg weight simplify cell integration.
- Pneumatic cylinders and closed-loop control boost reliability and lower maintenance interruptions.
| Spec | Value | Benefit |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | Supports high-volume 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 receive drop parts ready for quick installation. The CLX-BPO2 supports our lines in meeting volume targets without sacrificing quality.
Custom Specs for Your FTTH System
Shanghai Weiye OFC Equipment configures every order 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 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 Pantone-match sheath colors for fast field ID and consistent asset tags.
Branding and Print Options
Select LSZH/PVC/PE jackets based on route and safety rules. Custom legends/logos support inventory and warranty tracking.
Lengths, Packaging & Special Builds
Standard reel lengths are 1 km, 2 km, and 4 km with tailored reels and packaging to suit storage and handling. Choose bow-type flat or self-supporting designs and steel wire or FRP strength members to meet span and isolation needs.
| Option | Common choice | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and 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 detail final specs for straightforward QA on site.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line 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/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 inspection gates stop nonconforming items before they leave the factory.
Audit Trail and Compliance
Batch records link tests to reels/serials so audits and claims are easy 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 specifications confirmation and formatted data for quick review.
- Continuous test trends inform preventive maintenance and improve long-term reliability.
| Trial | Purpose | Result |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion resistance | 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 refined by volume and customization.
Typical prices vary widely—from about $30 to $1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket material, reel length, and design structure.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber optic grade, jacket material, and the structural type chosen for deployment.
Self-supporting designs and steel members increase material/labor. Custom sheath colors/logos/legends add setup time and impact pricing on small runs.
How Volume & Options Affect Cost
Longer put-ups and larger volumes reduce unit cost. Small quantities often carry setup fees and higher per-unit charges.
- 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.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Fiber grade | High impact | Right-size spec to budget |
| Sheath material | Medium | Evaluate LSZH vs PE |
| Order length / volume | High impact | Consolidate where possible |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align staffing and sites. Predictable windows cut downtime and control costs when a rollout is underway.
Typical production windows and capacity planning
Typical production windows run 4–5 days for orders under 100 km and 7–10 days for < 500 km. We schedule line capacity to track your milestones and to keep deliveries on time.
The service team issues production updates and tracking so installation teams know when reels arrive. For tight schedules, we hold contingency capacity to accelerate critical-path orders.
Why MOQ Matters
The MOQ is one kilometer. This reflects line setup such as wire and jacket die adjustments that consume start-up material and 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 readiness and application scenarios
Site conditions determine whether a self-supporting aerial, duct pull, or direct-buried run is the right choice for a project.
Deployment Considerations
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with appropriate members to manage sag/tension for long-term reliability.
Duct installations perform best with low-friction jackets and crush-resistant builds so pulling does not damage fibers. PE jackets are typical for underground and buried paths where moisture resistance matters.
Direct-buried designs require proper depth control per local codes and moisture-resistant jackets to protect the fiber core long-term.
Indoor Riser/Plenum & ONT
Indoor riser/plenum routes favor LSZH jackets to meet smoke/flame codes. Flat drop profiles strip cleanly 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 risk, and hardware fit. Standardized prep from the production line shortens install time and minimizes scrap.
| Scenario | Key design | Installer note |
|---|---|---|
| Aerial | 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 |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at penetrations |
Our approach delivers a consistent installation across indoor/outdoor transitions. That reduces callbacks, speeds 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 provide doc templates and clear install 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 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 requirements every time.
| Support area | Scope | Outcome |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| Testing | Lab + 100% reports | Full traceability |
| After-sales | Rapid replacement & root-cause | Lower 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 U.S. field acceptance.
A hardened production line, including CLX-BPO2 prep assets, reduces variability and speeds turnaround. Our equipment and machines standardize strip/stub lengths so installers see consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance design and cost to maximize service life. Dedicated 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 fiber optic and optic cable shipment with lab validation and responsive service.