Fiber-to-the-Home Cable Production: Manufacturing Process Explained
Did you know: over seventy percent of new U.S. broadband builds now use fiber networks that require high-precision manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment handles complete compact fiber unit manufacturing, from sourcing brand fibers like Fujikura® or Corning SMF-28e to complete test reports that deliver 100% QA.
Our drop cable designs are built for aerial, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), PVC, and polyethylene (PE) jacket options and arrangements from 1 to 4 cores. We provide single-mode OS1/OS2 and multimode OM2–OM4 grades plus G.652D and G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automated machines and precision equipment keep line speed steady and repeatability high. Typical lead times run four to five days for orders under 100 km and seven to ten days for < 500 km, with an MOQ of 1 km and free-replacement warranty for quality problems.
Continue to see how materials plus testing and support work together to reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment offers end-to-end manufacturing and lab testing for United States projects.
- Multiple jacket choices and fiber grades support indoor/outdoor environments.
- Automated lines and machines ensure stable quality and stable optical performance.
- Quick lead times, low minimums, and recognized brand fibers help plan procurement reliably.
- Comprehensive test reports and warranty support product reliability and compliance documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment provides tailored drop solutions with full test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment pairs specialized equipment with tight material control. We offer customized service and products for residential/MDU deployments. Every order comes with 100% quality assurance and complete test reports.
Our lab performs high-temperature, salt spray, and vibration tests to verify durability. Jacket options include LSZH, PVC, and PE. Designs offer 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 fully auditable shipments.
- Technical support for requirements, pilots, and scaling.
- 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, combining brand fiber choices with disciplined test flows.
Selecting Optical Fiber and Brands
We select fiber ribbon line to minimum bend radius, loss, and install environment. 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 offered to satisfy sourcing standards.
Strength Member Options
Strength members use dielectric FRP or galvanized steel wire. FRP is ideal where non-conductive runs are required. Steel wire adds tensile strength for long-span aerial runs and grounding needs.
Extrusion & Process Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility, and PE for UV/moisture resistance outdoors. Tight process control of temperature and capstan ratios stabilizes line speed and dimensional tolerances.
| Component | FRP | Metallic Steel |
|---|---|---|
| Primary use | Non-conductive runs | Aerial spans, high tensile |
| Key benefit | Light, non-corrosive | Very high tensile strength |
| Installation note | Simple terminations | Bonding/grounding required |
In-Process and Final Testing
Inline geometry/concentricity checks operate in-line. Final optical tests verify attenuation and return loss. Each order ships with a 100% test report and lab results from high-temperature, salt-spray, and vibration tests 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 first-article approvals provide traceability and compliance for U.S. programs.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment offers a focused portfolio of 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 keeps a small footprint for risers/ducts. It keeps bend loss low for simple routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs use a support messenger to handle tension. Choose FRP (dielectric) for electrical isolation or steel wire when bonding and higher tensile strength are required.
Core Layouts and Strength Members
We offer dielectric and metallic strength member configurations to meet safety/EMI requirements. Center loose tube and flat unitube types balance crush resistance and compact fiber unit 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 series is qualified for mechanical and optical quality before shipment.
| Type | Application | Strength member | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | FRP (dielectric) | LSZH |
| Self-supporting (aerial) | Aerial spans | Steel wire or FRP | PE |
| Central loose-tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Unitube flat | Low-count, easy strip | FRP or steel | LSZH or PE |
Production line equipment that ensures quality and speed
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and boost throughput for drop patch preparation.
Our production line integrates automated machines that cut and strip drop patch cords to increase output and cut labor 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 cutting and stripping for drop cable patch cords
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise reserved lengths. Pneumatic cylinder actuators provide quick, repeatable motion and minimize downtime.
PLC & Photoelectric for Precision
PLC logic + photoelectric sensors deliver precise positioning and closed-loop control. Inline checks feed control charts so operators can correct trends before out-of-control conditions occur.
| Feature | Spec | Benefit |
|---|---|---|
| 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 |
- Automated waste ejection and ergonomic feeders 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 Capabilities on 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 deploys 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 and photoelectric control enable precise detection and repeatable actuation. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Throughput & Cycle Time
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 17.5–35.0 mm. Reserved strength member stubs are adjustable from 7.0–11.0 mm to match common termination hardware.
Cutting FRP/Steel Members
The machine cleanly cuts FRP and steel wire strength elements while protecting neighboring fibers. Customized cutters are offered for nonstandard sizes to preserve precision.
- Auto-eject scrap and sensor-triggered start cut idle time.
- Compact size (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass ease integration into workcells.
- Cylinder-driven motion and closed-loop control improve line reliability and reduce maintenance downtime.
| Specification | Value | Benefit |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5 to 35.0 mm | Fits common connector processes |
| Stub (B) | 7.0 to 11.0 mm | Supports termination strength |
| Power/Size | 50W @ 110–220V; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes terminal prep so field teams get drop parts install-ready. The CLX-BPO2 supports our lines in meeting volume targets without sacrificing quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures every order 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 single-mode or multimode fiber. Options include OS1/OS2 plus OM2–OM4 plus G.652D and G.657 variants to align with optics and connector plans.
We match sheath colors to Pantone codes for fast field ID and consistent asset tagging.
Branding and Print Options
Select LSZH/PVC/PE jackets based on route and safety rules. Custom print legends and logos support inventory and 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 bow-type flat or self-supporting designs and FRP or steel members to fit span and isolation requirements.
| Choice | Common choice | Benefit |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Simpler staging and reels |
| Jacket | LSZH / PE / PVC | Indoor/Outdoor fit |
| Structure | Bow-type / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and delivers documentation that lists final specifications for easy on-site QA.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item has recorded acceptance data at ship.
Lab Testing: Heat, Salt Spray & Vibration
Our lab runs elevated-temperature exposure, salt spray corrosion, and vibration tests to qualify materials and assemblies. These tests recreate field stresses for indoor and outdoor use.
Full Test Reports for Every Reel
Every fiber optic cable includes a 100% test report that logs attenuation, return loss, and geometry where applicable. Final inspection gates stop nonconforming items before they leave the factory.
Traceability & Compliance
Batch records link tests to reels/serials so audits and warranty claims are simple to verify. Documentation uses standard 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 data for quick review.
- Ongoing trend analysis inform preventive maintenance and improve long-term reliability.
| Test | Purpose | Outcome |
|---|---|---|
| Heat exposure | Thermal stability | Pass at target temperature |
| Salt spray | Corrosion resistance | Qualified for outdoor use |
| Vibration | Mechanical robustness | Reduced field failures |
FTTH Drop Cable Pricing & Cost Drivers
Budgeting for a drop run starts with fiber and jacket choices and is refined by volume and customization.
Typical prices range broadly—from about $30 to $1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket chemistry (LSZH, PVC, PE), reel length, and design structure.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, sheath material, and the chosen structure 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.
Order length, volume, and customization impact on price
Longer put-ups and larger volumes reduce unit cost. Small quantities often carry setup fees and higher unit prices.
- Changeovers and special cutters extend 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 | Price impact | Recommendation |
|---|---|---|
| Optical grade | Large | Balance spec vs. budget |
| Sheath material | Medium | Evaluate LSZH vs PE |
| Order 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 reduce downtime and help control cost 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 match your rollout 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 pull in critical-path orders.
Why MOQ Matters
The MOQ is one kilometer. This reflects line setup such as wire/die adjustments that use startup material and generate scrap.
We review your put-ups and staging to choose reel sizes that cut waste and handling. Staggered batches can balance inventory holding with more frequent small-site deliveries.
Installation Scenarios & Readiness
Site conditions dictate whether a self-supporting aerial, ducted pull, or direct burial is the right choice for a project.
Aerial, duct, and direct-buried deployment considerations
For aerial runs, Shanghai Weiye OFC Equipment recommends 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 common for underground and buried paths where moisture resistance is needed.
Direct-buried designs need correct burial depth per local codes and moisture barriers to protect the optic core over time.
Indoor riser/plenum distribution and ONT termination
Indoor riser/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 needs, lightning exposure, and hardware fit. Standardized prep from the production line shortens install time and reduces scrap.
| Deployment | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Underground duct | Low-friction, crush-resistant | Use pull tape and proper lubricant |
| Direct burial | PE with moisture barrier | Follow depth/warning tape codes |
| 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.
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 pre-production builds. We provide doc templates and clear install notes so field crews share a unified plan.
After-sales service includes fast response, RCA, and corrective action. 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.
- Configuration control so shipped items match agreed specs consistently.
| Area | Scope | Benefit |
|---|---|---|
| Tech/Eng | Specs + pilots | Reduced field issues |
| Testing | Lab + 100% reports | Traceable quality |
| Service | Rapid replacement & root-cause | Minimized downtime |
Final Thoughts
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
We deliver customized FTTH drop solutions that pair material choices with validated manufacturing and lab testing. Every reel includes a 100% test report and documented lab 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 set standardize strip and stub lengths so installers see 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 guides scheduling, logistics, and after-sales care so your deployment stays 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 service.