Fiber-to-the-Home Cable Production: Manufacturing Process Explained
Did you know: over seventy percent of U.S. broadband rollouts now use fiber networks that need precise manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment runs end-to-end fiber secondary coating line manufacturing, from selecting brand fibers like Fujikura® or Corning SMF-28e to final test reports that deliver 100% QA.
Our FTTH drop designs suit aerial, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and PE jacket options and core counts from 1–4 cores. We supply OS1/OS2 and multimode 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 stabilize line speed and maximize repeatability. 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 free-replacement warranty for quality problems.
Keep reading to see how our materials, tests, and support work together to reduce lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment delivers complete production and laboratory testing for U.S. deployments.
- A range of jacket options and optical grades support indoor/outdoor environments.
- Automated lines and machines deliver consistent quality and stable optical performance.
- Quick lead times, low minimums, and brand fiber options help plan procurement reliably.
- Comprehensive test reports and after-sales warranty back product reliability and compliance documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment provides customized drop cables with complete test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment combines specialized equipment with tight material control. We offer customized service and products for residential and MDU rollouts. Every order comes with 100% quality assurance and full test reports.
Our lab runs high-temperature, salt spray, and vibration tests to verify durability. Jacket options cover LSZH, PVC, and PE. Designs offer flat bow-type and self-supporting styles and use 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 fixtures and calibration minimize variation so every cable matches operator specs.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, combining brand fiber choices with rigorous test routines.
Fiber Selection & Brand Options
We match fiber draw tower to minimum bend radius, loss, 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 satisfy sourcing standards.
Strength member integration
Strength members use FRP (dielectric) or galvanized steel wire. FRP is ideal where non-conductivity is necessary. Steel wire provides tensile strength for longer aerial spans and bonding/grounding needs.
Jacket extrusion and process 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 extruder temperature and capstan speed stabilizes line speed and critical dimensions.
| Member | FRP | Steel wire |
|---|---|---|
| Use case | Non-conductive runs | Aerial spans, high tensile |
| Key benefit | Light, non-corrosive | High strength |
| Installer note | Easier terminations | Bonding/grounding required |
Testing & Verification
Inline geometry/concentricity checks run during manufacturing. Final optical tests verify attenuation and reflectance. Each order includes a 100% test report and lab results from high heat, salt fog, and vibration trials 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. Lot records and FAI 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 cover tight indoor routes and exposed aerial spans. Each option pairs tested materials with geometry tuned for field termination and consistent optical performance.
The flat bow-type drop minimizes 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 dielectric FRP for non-conductive runs or steel messenger when bonding and extra tensile strength are required.
Layouts & Strength Members
We offer both dielectric and metallic strength member configurations to meet safety/EMI requirements. Center loose tube and unitube flat types balance crush resistance and Fiber coloring machine for quick termination.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor UV and moisture resilience. Each series is validated for mechanical and optical quality before shipment.
| Design | Best use | Strength member | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | FRP (dielectric) | LSZH |
| Self-supporting (aerial) | Aerial spans | FRP/Steel | Polyethylene |
| Central loose-tube | Higher-count builds | Dielectric FRP | LSZH/PE |
| Flat unitube | Low-count, easy strip | FRP/Steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
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 ~20 terminals per minute in production.
Automated Cut/Strip for Drop Cords
The equipment strips LSZH and PVC jackets and trims FRP/steel members to precise reserved lengths. Cylinder-driven actuators deliver fast, repeatable motion and minimize downtime.
PLC & Photoelectric for Precision
PLC logic + photoelectric sensors deliver precise positioning and feedback control. Inline checks update SPC charts so operators can correct trends before out-of-control conditions occur.
| Feature | Capability | Result |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | High throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Material handling | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Process control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic loading maintain clean workcells.
- Process control plans capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without compromising accuracy.
CLX-BPO2 auto-stripping machine capabilities in 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 increase throughput 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 motion. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Throughput & Cycle Time
Typical operation speed is ~1.5 seconds per cycle. This converts to steady throughput under continuous line 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 set between 7.0 and 11.0 mm to match common termination hardware.
Cutting FRP/Steel Members
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Customized cutters are available for nonstandard sizes to maintain 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.
- Pneumatic cylinders and closed-loop control boost reliability and reduce maintenance downtime.
| Specification | Value | Why it matters |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Reserved 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 sacrificing quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures each build to meet 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 along with G.652D and G.657 variants to align with 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 to suit route and safety requirements. Custom print legends and logos support inventory and warranty tracking.
Put-Ups, Packaging, and Structures
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 fit span and isolation requirements.
| Option | Typical | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Less staging, easier reels |
| Jacket | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Design | Bow-type / Self-supporting | Routing and span flexibility |
As a supplier, Shanghai Weiye aligns runs to your schedule and provides docs 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 has recorded acceptance data at ship.
Environmental and Mechanical Tests
Our lab conducts elevated-temperature exposure, salt fog corrosion, and vibration tests to qualify materials and 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.
Traceability and compliance
Lot/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.
- Line checks and final inspection reduce field failures and cut warranty events.
- Quality packages include specifications confirmation and formatted test data for quick review.
- Ongoing trend analysis inform preventive maintenance and improve long-term reliability.
| Test | Why | Outcome |
|---|---|---|
| High-temperature | Thermal stability | Validated heat endurance |
| Salt-fog | Corrosion resistance | Qualified for outdoor use |
| Mechanical vibration | Resistance to vibration | Reduced field failures |
FTTH Drop Cable Pricing & Cost Drivers
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, jacket material, length, and design structure.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber grade, jacket material, and the structural type chosen for deployment.
Self-supporting structures and steel strength elements increase material/labor. Custom sheath colors/logos/legends add setup time and influence price for short runs.
How Volume & Options Affect Cost
Longer put-ups and larger volumes reduce unit cost. Short runs often include setup charges 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 align price quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Driver | Effect on price | Recommendation |
|---|---|---|
| Optical grade | High impact | Right-size spec to budget |
| Sheath material | Medium | Evaluate LSZH vs PE |
| Order length / volume | Large | Consolidate runs to cut unit cost |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align staffing and sites. Predictable schedules cut 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 plan capacity to track your milestones and to keep deliveries on time.
The service team provides updates/tracking so installation teams know when reels arrive. For tight schedules, we hold contingency capacity to accelerate critical-path orders.
Minimum order quantity and why it 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. 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, duct pull, or direct-buried run is the right choice for a project.
Aerial vs Duct vs Direct-Buried
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with appropriate members to control sag and tension for long-term reliability.
Duct installations work best with low-friction jackets 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 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 prefer LSZH to meet smoke/flame codes. Flat drop profiles strip cleanly and present controlled stubs for quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding needs, lightning exposure, and hardware compatibility. Standardized prep from the production line shortens install time and minimizes scrap.
| Deployment | Key design | Field note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Duct | Low-friction jacket, crush resistance | Use pull tape + lubricant |
| Direct-buried | PE with moisture barrier | Follow local depth and warning tape rules |
| Indoor | LSZH with 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 testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements 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 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.
- Schedule coordination for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed specs consistently.
| Area | What we do | Outcome |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Reduced field issues |
| QA/Testing | Lab + 100% reports | Traceable quality |
| Service | 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 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 get consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance design and cost to extend service life. Dedicated customer support covers scheduling/logistics/after-sales 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.