Fiber-to-the-Home Cable Production: How the Manufacturing Process Works
Did you know: over 70% of U.S. broadband rollouts now use fiber networks that demand precise manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment runs end-to-end FTTH cable production line manufacturing, from sourcing brand fibers like Fujikura® or Corning SMF-28e to final test reports that deliver 100% QA.
Our drop cable designs suit overhead, ducted, and direct burial installation, with low-smoke zero-halogen (LSZH), PVC, and PE jacket options and core counts from 1 to 4 cores. We offer OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and ITU-T G.657 variants, Pantone sheath colors, and custom logo printing.
Automation and precision equipment stabilize line speed and repeatability high. Typical lead times are four to five days for orders < 100 km and seven to ten days under 500 km, with an MOQ of 1 km and warranty for free replacement on quality issues.
Read on to understand 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 offers end-to-end manufacturing and lab testing for United States projects.
- Multiple jacket choices and fiber grades cover indoor/outdoor environments.
- Automated lines and machines deliver stable quality and reliable optical performance.
- Fast lead times, low MOQ, and recognized brand fibers help plan procurement reliably.
- Complete reports and warranty support product reliability and compliance documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment provides customized drop cables with complete test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment combines specialized equipment with tight material control. We provide custom builds and services for single-family and MDU rollouts. Every order includes 100% quality assurance and complete test reports.
Our lab conducts high heat, salt-fog, and vibration testing to validate durability. Jacket options include LSZH, PVC, and PE. Designs cover bow-type flat and self-supporting styles and use brand fibers such as Fujikura and Corning SMF-28e.
- Controlled production lines and production checks for auditable shipments.
- Technical support for specification reviews, trials, and volume ramp.
- Modern fixtures and calibration reduce variability so every cable matches operator specs.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with disciplined test flows.
Selecting Optical Fiber and Brands
We align Fiber coloring machine to bend radius, loss, and install environment. 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 meet procurement standards.
Strength Member Options
Strength members employ dielectric FRP or galvanized steel wire. FRP is preferred where non-conductive runs are required. Steel wire provides tensile strength for long-span aerial runs and grounding needs.
Extrusion & Process Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility and ease of handling, and PE for UV/moisture resistance outdoors. Closed-loop control of temperature and capstan ratios keeps line speed stable and dimensional tolerances.
| Member | FRP | Steel wire |
|---|---|---|
| Primary use | Non-conductive runs | High-tension aerial runs |
| Advantage | Light, non-corrosive | Very high tensile strength |
| Installer note | Simple terminations | Requires grounding |
In-Process and Final Testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests verify loss and return loss. Each order includes a full 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 support traceability and compliance for U.S. programs.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment provides a compact portfolio of FTTH drop designs that fit indoor risers and long aerial runs. Each option pairs tested materials with geometry tuned for field termination 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 designs for aerial spans
Self-supporting FTTH drop designs include a messenger element to handle tension. Choose FRP (dielectric) for electrical isolation or steel messenger when bonding and higher tensile strength are required.
Layouts & Strength Members
We provide both dielectric and metallic strength member configurations to match safety and EMI rules. Central loose-tube and flat unitube types balance crush resistance and fiber secondary coating line for quick termination.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor UV and moisture resilience. Each family is validated for mechanical and optical quality before shipment.
| Design | Best use | Strength element | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | Dielectric FRP | LSZH |
| Self-supporting | Overhead spans | Steel wire or FRP | Polyethylene |
| Central loose-tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Unitube flat | Low-count, easy strip | FRP/Steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment reduce manual handling and increase throughput for drop patch preparation.
Our production line uses automated machines that cut/strip drop cords to raise throughput and cut labor variability.
The CLX-BPO2 auto-stripping machine runs under PLC and photoelectric control. One cycle is ~1.5 s, giving ~20 terminals per minute in production.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH and PVC jackets and trims FRP/steel members to precise reserved lengths. Pneumatic cylinder actuators provide quick, repeatable motion and minimize downtime.
PLC/photoelectric control for precision and repeatability
PLC logic and photoelectric sensors give exact positioning and feedback control. Inline checks update SPC charts so operators can adjust drifts before out-of-control conditions occur.
| Feature | Capability | Benefit |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Process control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic feeders keep the line clean.
- Process control plans capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets 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 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/photoelectric control deliver exact detection and repeatable motion. That control keeps strip and stub lengths within tight tolerances.
Line Speed
Typical operation speed is ~1.5 seconds per cycle. This translates to steady throughput under normal production conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets 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 fit common termination hardware.
Cutting FRP/Steel 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 preserve precision.
- Automatic waste ejection and sensor start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass ease integration into workcells.
- Pneumatic cylinders and closed-loop control improve line reliability and lower maintenance interruptions.
| Specification | Rating | Why it matters |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Reserved stub (B) | 7.0–11.0 mm | Supports termination strength |
| Power/Size | 110–220V, 50W; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes terminal prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 supports our lines in meeting volume targets without compromising quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures each build to meet your network requirements and simplify deployment. We pair concise options with predictable manufacturing windows so your teams get install-ready reels.
Choose 1 to 4 cores with SM or MM fiber. Options include OS1/OS2 plus OM2–OM4 plus G.652D and 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 print legends and logos aid inventory/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 FRP or steel members to fit span and isolation requirements.
| Choice | Common choice | Benefit |
|---|---|---|
| Length | 1 / 2 / 4 km | Less staging, easier reels |
| Sheath | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Design | 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.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment builds checkpoints into production so every item ships with recorded acceptance data.
High-temperature, salt spray, and vibration laboratory testing
Our lab conducts high-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials and assemblies. These tests simulate field stresses for indoor and outdoor use.
Per-Reel 100% Reports
Every fiber optic cable ships with 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.
Audit Trail and Compliance
Batch records link tests to reels/serials so audits and claims are easy to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection reduce field failures and lower warranty events.
- QA packages include specifications confirmation and formatted test data for rapid review.
- Ongoing trend analysis drive preventive maintenance and raise long-term reliability.
| Trial | Why | Outcome |
|---|---|---|
| Heat exposure | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion resistance | 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 range broadly—from about $30–$1,000 per unit—based on fiber grade, jacket material, length, and design structure.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber optic grade, jacket material, and the chosen structure for deployment.
Self-supporting structures and steel strength elements raise material and labor input. Custom colors, logos, and print legends add setup time and influence price for short runs.
Length/Volume/Customization Impact
Longer put-ups and larger volumes lower unit cost. Small quantities often carry setup fees and higher unit prices.
- Changeovers and special cutters extend lead time and add cost.
- Clear RFQs with schedule alignment let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Frameworks 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 staffing 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 < 500 km. We schedule line capacity to match your rollout milestones and to keep deliveries on time.
The service team issues production updates and 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 line setup such as wire/die adjustments that use startup material and generate scrap.
We review your length and staging plans to select reels to reduce waste/handling. Staggered batches can balance inventory with more frequent small-site deliveries.
Where and How to Deploy
On-site conditions dictate whether a self-supporting span, ducted pull, or direct-buried run is the best fit for a project.
Aerial vs Duct vs Direct-Buried
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 work 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 matters.
Direct-buried designs need correct burial depth per local codes and moisture barriers to protect the optic core over time.
Indoor Distribution and ONT
Indoor riser/plenum routes favor LSZH jackets to meet flame and smoke rules. Flat drop cable forms strip clean and present controlled stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding requirements, lightning risk, and hardware fit. Standardized prep from the production line reduces install time and reduces scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Underground duct | Low-friction, crush-resistant | 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 ensures a consistent install experience across indoor outdoor transitions. That leads to fewer callbacks, faster activations, and reliable field performance for your system.
Support from Spec to Service
Our team coordinates testing, scheduling, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements capture through approved drawings and pilot builds. We deliver documentation 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.
- Round-the-clock availability for status and technical support.
- Warranty includes free replacement for confirmed quality issues.
- Coordination of line schedules for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed specs consistently.
| Support area | What we do | Outcome |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Reduced field issues |
| QA/Testing | Lab trials & 100% test reports | Full traceability |
| After-sales | Rapid replacement & root-cause | Lower downtime |
Final Thoughts
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
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 U.S. field acceptance.
A hardened production line, including CLX-BPO2 prep assets, cuts variability and speeds turnaround. Our equipment and machines standardize strip and stub lengths so installers see consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance design and cost to extend service life. Dedicated customer support covers scheduling/logistics/after-sales 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 service.