Fiber-to-the-Home Cable Production: Manufacturing Process Explained
Quick fact: in excess of seventy percent of new U.S. broadband builds now rely on fiber networks that need high-precision manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment manages complete Fiber cable sheathing 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 aerial, underground, and direct-buried installation, with LSZH, PVC, and polyethylene (PE) jacket options and core counts from 1–4 cores. We supply single-mode OS1/OS2 and multimode OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and logo printing.
Automation and precision equipment keep line speed steady and maximize repeatability. Typical lead times are 4–5 days for orders < 100 km and seven to ten days for < 500 km, with an MOQ of 1 km and free-replacement warranty for quality problems.
Keep reading to understand how materials, 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 optical grades cover different install environments.
- Automated lines and machines ensure stable quality and stable optical performance.
- Quick lead times, low MOQ, and brand fiber options support reliable procurement planning.
- Complete reports and after-sales warranty back product reliability and compliance documentation needs.
Expert FTTH manufacturing 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 focused supplier and manufacturer, Shanghai Weiye OFC Equipment pairs purpose-built equipment with stringent material control. We provide customized service and products for residential/MDU deployments. Every order includes 100% quality assurance and complete test reports.
Our lab runs high heat, salt spray, and vibration testing to validate durability. Jacket options include LSZH, PVC, and PE. Designs cover flat bow-type and self-supporting styles and support brand fibers such as Fujikura® and Corning SMF-28e.
- Documented line control and in-process checks for fully auditable shipments.
- Technical support for specs, trials, and ramp to volume.
- Modern fixturing 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 strict test routines.
Selecting Optical Fiber and Brands
We align fiber draw tower to minimum bend radius, attenuation, 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 meet procurement standards.
Strength member integration
Strength members employ FRP (dielectric) or galvanized steel wire. FRP is preferred where non-conductive runs are required. Steel wire adds 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 PE for UV/moisture resistance outdoors. Tight process control of extruder temperature and capstan speed keeps line speed stable and dimensional tolerances.
| Component | Dielectric FRP | Metallic Steel |
|---|---|---|
| Primary use | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Lightweight, inert | Very high tensile strength |
| Installer note | Easier terminations | Requires grounding |
Inline and final testing
Inline geometry and concentricity checks operate in-line. Final optical tests verify attenuation and return loss. 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 under 100 km in 4–5 days 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 provides a compact portfolio of drop designs that fit indoor risers and long aerial runs. Each option combines tested materials with field-termination geometry and consistent optical performance.
The bow-type flat drop cable minimizes footprint for risers/ducts. It reduces bend loss for simple routing in MDU corridors and hallways.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs use a messenger element to handle tension. Choose dielectric FRP for electrical isolation or steel wire when bonding and extra tensile strength are required.
Core Layouts and Strength Members
We offer 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 UV and moisture resilience. Each family is qualified for mechanical/optical performance before shipment.
| Type | Application | Strength member | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| 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/Steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and boost throughput for drop patch preparation.
Our production line uses automated machines that cut and strip drop patch cords to increase output and cut labor variability.
The CLX-BPO2 auto-stripping machine runs under PLC and 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 and PVC jackets and trims FRP or steel strength members to precise reserved lengths. Cylinder-driven actuators deliver fast, repeatable motion and low downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors give exact positioning and feedback control. Inline checks update SPC charts so operators can correct trends before out-of-control conditions occur.
| Item | Capability | Result |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Drive | Cylinder-based | High speed and reliability |
| Material handling | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Automated waste ejection and ergonomic loading keep the line clean.
- PCPs document calibration and key parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without compromising accuracy.
What the CLX-BPO2 Adds
The CLX-BPO2 provides industrial-grade strip/trim to our line, cutting cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment deploys 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 and photoelectric control deliver exact 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 translates to steady throughput under continuous line conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable strip length from 17.5 to 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 adjacent fibers. Customized cutters are available for non-standard cross-sections to preserve precision.
- Auto-eject scrap and sensor start cut idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass ease integration into workcells.
- Pneumatic cylinders and PLC/photoelectric control improve line reliability and reduce maintenance downtime.
| Spec | Rating | 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 supports our lines in meeting volume targets without sacrificing quality.
Customized specifications to fit 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 receive ready-to-install products.
Choose 1–4 core designs with single-mode or multimode fiber. Options include OS1/OS2 plus OM2–OM4 along with 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.
Branding and Print Options
Select LSZH/PVC/PE jackets based on route and safety rules. Custom print legends and logos aid inventory/warranty tracking.
Put-Ups, Packaging, and Structures
Standard reel lengths 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 fit span and isolation requirements.
| Option | Common choice | Benefit |
|---|---|---|
| Reel length | 1, 2, or 4 km | Less staging, easier reels |
| Sheath | LSZH, PE, PVC | Indoor/Outdoor fit |
| Design | Bow-type / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye schedules runs to your plan and delivers documentation 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 has recorded acceptance data at ship.
High-temperature, salt spray, and vibration laboratory testing
Our lab conducts elevated-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials and assemblies. These tests recreate field stresses for indoor and outdoor use.
100% test reports for every cable
Every fiber optic cable ships with a 100% test report that records loss, return loss, and key geometry where applicable. Final inspection gates prevent nonconforming shipments before they leave the factory.
Audit Trail and Compliance
Lot/batch records link tests to reels/serials so audits and claims are easy to verify. Documentation follows common customer templates to accelerate approvals and receiving inspection.
- In-line checks plus 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.
| Trial | Why | Result |
|---|---|---|
| High-temperature | Material stability | Validated heat endurance |
| Salt-fog | Corrosion robustness | Qualified for outdoor use |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
Pricing and cost drivers for FTTH drop cable
Budget planning for a drop begins with fiber/jacket selection 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 material, length, and structural design.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber optic grade, sheath material, and the chosen structure 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.
Order length, volume, and customization impact on price
Longer put-ups and larger volumes reduce unit cost. Small quantities often include setup charges and higher per-unit charges.
- Line changeovers and custom tooling increase lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Factor | Effect on price | Guidance |
|---|---|---|
| Fiber grade | High impact | Right-size spec to budget |
| Sheath material | Medium | Compare LSZH vs. PE for total cost |
| Length/Volume | Large | Consolidate runs to cut unit cost |
Lead times, MOQ, and delivery for the United States
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews and sites. Predictable windows cut downtime and control costs when a rollout is underway.
Typical production windows and 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 maintain on-time delivery.
The service team provides updates/tracking so installation teams know when reels arrive. For tight schedules, we reserve contingency capacity to accelerate 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 put-ups and staging to select reels to reduce waste/handling. Staggered batches can balance inventory with frequent, smaller deliveries to job sites.
Installation Scenarios & Readiness
On-site conditions determine whether a self-supporting span, duct pull, or direct burial is the right choice for a project.
Aerial vs Duct vs Direct-Buried
For aerial runs, Shanghai Weiye OFC Equipment advises self-supporting designs with correct strength members to control sag and 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 fiber core long-term.
Indoor Distribution and ONT
Indoor riser and plenum routes favor LSZH jackets to meet smoke/flame codes. Flat drop cable forms strip cleanly and present controlled stubs for quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding requirements, lightning exposure, and hardware compatibility. Standardized prep from the production line reduces install time and minimizes scrap.
| Scenario | 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 burial | PE with moisture barrier | Follow depth/warning tape codes |
| Indoor | LSZH with tight-bend support | Maintain bend radius at penetrations |
Our approach ensures a consistent install experience across indoor/outdoor transitions. That reduces callbacks, speeds activations, and stable field performance for your system.
End-to-end support and after-sales service
Our team coordinates testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements capture through approved drawings and pilot builds. We deliver documentation templates and clear install notes so field crews work from the same 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.
- Round-the-clock availability for status updates and technical guidance.
- Warranty includes free replacement for confirmed quality issues.
- Coordination of line schedules for expedites and urgent changes.
- Configuration control so shipped items match agreed specs consistently.
| Support area | Scope | Benefit |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| Testing | Lab + 100% reports | Full traceability |
| Service | Rapid replacement & root-cause | Lower downtime |
Final Thoughts
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 lab trials to support field acceptance in the United States.
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 to jacket, printing, and packaging, we balance performance and cost to extend service life. Dedicated customer support guides scheduling, logistics, and after-sales care so your deployment stays on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with lab validation and responsive support.
