Fiber-to-the-Home Cable Production: Step-by-Step Manufacturing Process
Did you know: more than seventy percent of U.S. broadband rollouts now use fiber networks that demand precise manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment handles end-to-end fiber secondary coating line manufacturing, from sourcing brand fibers like Fujikura® or Corning® SMF-28e to final test reports that guarantee full quality assurance.
Our FTTH drop designs fit aerial, underground, and direct burial installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and polyethylene (PE) jacket options and core counts from 1 to 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 custom logo printing.
Automated machines and high-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 free-replacement warranty for quality problems.
Keep reading to learn how materials, testing, and support combine to lower lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment delivers complete production and laboratory testing for United States projects.
- Multiple jacket choices and fiber grades support different install environments.
- Automated production lines ensure consistent quality and reliable optical performance.
- Quick lead times, low minimums, and recognized brand fibers keep procurement predictable.
- Comprehensive test reports and after-sales warranty support product reliability and documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment delivers tailored drop solutions with complete test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment pairs specialized equipment with stringent material control. We provide custom builds and services for residential/MDU deployments. Every order includes full QA coverage and full test reports.
Our lab conducts high heat, salt-fog, and vibration testing to verify durability. Jacket options cover 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 production checks for fully auditable shipments.
- Technical support for specification reviews, trials, and volume ramp.
- Modern fixturing and calibration reduce variability so every cable meets carrier standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, pairing brand fiber choices with disciplined test flows.
Selecting Optical Fiber and Brands
We match fiber ribbon line 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 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 provides tensile strength for longer aerial spans and bonding/grounding needs.
Extrusion & Process Control
Jacket options include LSZH for flame/smoke 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.
| Member | Dielectric FRP | Metallic Steel |
|---|---|---|
| Primary use | Electrical isolation | High-tension aerial runs |
| Advantage | Light, non-corrosive | Very high tensile strength |
| Installation note | Easier terminations | Bonding/grounding required |
Inline and final testing
Inline geometry/concentricity checks operate in-line. Final optical tests confirm loss and return loss. Each order ships with a full test report and lab results from high-temperature, salt-spray, and vibration trials to confirm handling for drop terminations and field use.
Typical lead times are under 100 km in 4–5 days and 7–10 days for < 500 km. Material lot records and first-article approvals provide traceability and compliance for U.S. programs.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment provides a focused portfolio of FTTH 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 flat bow-type drop minimizes footprint for risers and conduit. It keeps bend loss low for easy routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs use a messenger element to carry tensile loads. Choose FRP (dielectric) for non-conductive runs or steel messenger when bonding/grounding and higher tensile strength are required.
Layouts & Strength Members
We offer both dielectric and metallic strength member configurations to match safety and EMI rules. Central loose-tube and unitube flat types balance crush resistance and Fiber draw tower for quick termination.
Indoor/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.
| Design | Best use | Strength member | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | Dielectric FRP | LSZH |
| Self-supporting (aerial) | Aerial spans | Steel wire or FRP | PE |
| Central loose-tube | Higher-count builds | 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 raise throughput and reduce operator variability.
The CLX-BPO2 automated stripper runs under PLC and photoelectric control. One cycle is about 1.5 seconds, giving ~20 terminals per minute in production.
Auto Cut & Strip Capabilities
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise reserved lengths. Cylinder-driven actuators deliver fast, repeatable motion and low downtime.
PLC & Photoelectric for Precision
PLC logic and photoelectric sensors deliver precise positioning and feedback control. Inline checks feed control charts so operators can adjust drifts before defects grow.
| Feature | Capability | Benefit |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic feeders maintain clean workcells.
- PCPs document calibration and key parameters.
- Integrated assets and trained operators help meet FTTH volume goals without sacrificing accuracy.
CLX-BPO2 auto-stripping machine capabilities in our line
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, cutting cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment deploys the CLX-BPO2 to raise output and standardize terminal 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 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 ~1.5 seconds per cycle. This enables steady throughput under normal production conditions.
Supported jacket and reserved strength lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable jacket strip length from 17.5–35.0 mm. Reserved stubs are adjustable from 7.0–11.0 mm to match common termination hardware.
FRP & Steel Member Handling
The machine cleanly cuts FRP and steel wire strength elements while protecting adjacent fibers. Custom tooling are available for non-standard cross-sections to preserve precision.
- Automatic waste ejection and sensor-triggered start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight simplify cell integration.
- Pneumatic cylinders and closed-loop control boost reliability and lower maintenance interruptions.
| Spec | Rating | Benefit |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | Supports high-volume runs |
| Strip lengths (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Reserved stub (B) | 7.0 to 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 terminal prep so field teams get drop parts install-ready. The CLX-BPO2 helps our production lines meet volume goals without compromising quality.
Custom Specs for Your FTTH System
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 1–4 core designs with single-mode or multimode fiber. Options include OS1, OS2, and OM2–OM4 along with G.652D and G.657 variants to align with optics and connector plans.
We match sheath colors to Pantone codes for quick field identification 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.
Length options, packaging, and special structures
Standard reel lengths are 1/2/4 km with tailored 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.
| Choice | Common choice | Benefit |
|---|---|---|
| Length | 1 / 2 / 4 km | Less staging, easier reels |
| Sheath | LSZH / PE / PVC | Indoor/Outdoor fit |
| Design | Flat bow / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye schedules runs to your plan and delivers documentation that lists final specifications for easy on-site QA.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment builds checkpoints into production so every item has recorded acceptance data at ship.
Environmental and Mechanical Tests
Our lab conducts elevated-temperature exposure, salt spray corrosion, and vibration tests to qualify materials and assemblies. These tests simulate field stresses for indoor/outdoor applications.
Full Test Reports for Every Reel
Every fiber optic cable ships with a 100% test report that records loss, return loss, and key geometry where applicable. Final QC gates prevent nonconforming shipments before they leave the factory.
Traceability and compliance
Batch records tie test data to reels and serials so audits and warranty claims are simple to verify. Documentation follows common customer templates to accelerate approvals and receiving inspection.
- In-line checks plus final inspection prevent field failures and cut warranty events.
- Quality packages include spec confirmation and formatted data for quick review.
- Continuous test trends inform preventive maintenance and improve long-term reliability.
| Test | Purpose | Outcome |
|---|---|---|
| High-temperature | Material stability | Validated heat endurance |
| Salt spray | Corrosion resistance | Outdoor suitability |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
Cost Drivers and Pricing
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, reel length, and design structure.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, jacket material, and the chosen structure for deployment.
Self-supporting structures and steel members increase material/labor. Custom sheath colors/logos/legends add setup and influence price for short runs.
Order length, volume, and customization impact on price
Longer reels and higher volume orders reduce unit cost. Small quantities often include setup charges 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.
| Driver | Price impact | Guidance |
|---|---|---|
| Optical grade | High impact | Right-size spec to budget |
| Jacket type | Medium | Evaluate LSZH vs PE |
| Length/Volume | High impact | Consolidate runs to cut unit cost |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align staffing and sites. Predictable schedules reduce 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 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 compressed schedules, we reserve contingency capacity to pull in critical-path orders.
Minimum order quantity and why it matters
The MOQ is 1 km. 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. Batch releases can balance inventory holding with frequent, smaller deliveries to job sites.
Installation readiness and application scenarios
Site conditions determine whether a self-supporting span, duct pull, or direct-buried run is the best fit 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 manage sag/tension for long-term reliability.
Duct installations perform best with low-friction sheaths and crush-resistant constructs 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 and plenum routes favor LSZH jackets to meet flame and smoke rules. Flat drop cable forms strip cleanly and present controlled strength stubs for quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware compatibility. Standardized prep from the production line reduces install time and minimizes scrap.
| Scenario | Key design | Installer note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Underground duct | Low-friction jacket, crush resistance | Use pull tape + lubricant |
| Direct-buried | PE with moisture barrier | Follow local depth and warning tape rules |
| Interior | LSZH with tight-bend support | Maintain bend radius at wall penetrations |
Our approach delivers a consistent installation across indoor/outdoor transitions. That leads to fewer 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 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 installation 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 updates and technical guidance.
- Warranty with free replacement if any quality problems are confirmed.
- Schedule coordination for expedites and urgent changes.
- Configuration control so shipped items match agreed specs consistently.
| Support area | Scope | Benefit |
|---|---|---|
| Engineering | Spec review & pre-production builds | Reduced field issues |
| Testing | Lab + 100% reports | Full traceability |
| Service | Rapid replacement & root-cause | Lower downtime |
Wrap-Up
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 lab 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 see consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance performance and cost to maximize service life. Dedicated customer support guides scheduling, logistics, and after-sales care so your deployment stays on plan.
Contact Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every fiber optic and optic cable shipment with lab validation and responsive service.
