Fiber-to-the-Home Cable Production: Step-by-Step Manufacturing Process
Surprising fact: over 70% of new U.S. broadband builds now depend on fiber networks that demand precise manufacturing to meet performance goals.
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 deliver 100% QA.
Our drop cable designs suit aerial, ducted, and direct-buried installation, with LSZH, polyvinyl chloride (PVC), and PE jacket options and core counts from 1 to 4 cores. We offer single-mode OS1/OS2 and multimode OM2–OM4 grades plus ITU-T 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 4–5 days for orders under 100 km and seven to ten days under 500 km, with an min. order of 1 km and warranty covering free replacement for confirmed quality issues.
Continue to see how our materials, tests, and support work together to reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment delivers end-to-end manufacturing and lab testing for United States projects.
- A range of jacket options and optical grades cover indoor/outdoor environments.
- Automated production lines ensure consistent quality and stable optical performance.
- Fast lead times, low MOQ, and recognized brand fibers support reliable procurement planning.
- Comprehensive test reports and after-sales warranty back product reliability and compliance 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 purpose-built equipment with tight material control. We offer custom builds and services for residential and MDU rollouts. Every order comes with full QA coverage and complete test reports.
Our lab conducts high-temperature, salt spray, and vibration tests to validate durability. Jacket options cover LSZH, PVC, and PE. Designs offer bow-type flat and self-supporting styles and use brand fibers such as Fujikura and Corning® SMF-28e.
- Documented line control and production checks for auditable shipments.
- Technical support for specification reviews, trials, and volume ramp.
- Modern fixturing and calibration reduce variability so every cable meets carrier standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are built around network requirements, pairing brand fiber choices with strict test routines.
Selecting Optical Fiber and Brands
We match fiber secondary coating line to minimum bend radius, loss, and install environment. 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 meet procurement standards.
Strength Member Options
Strength members employ FRP (dielectric) or galvanized steel wire. FRP is preferred where non-conductivity is necessary. Steel wire adds tensile strength for longer aerial spans and bonding/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 temperature and capstan ratios keeps line speed stable and dimensional tolerances.
| Component | Dielectric FRP | Metallic Steel |
|---|---|---|
| Use case | Electrical isolation | High-tension aerial runs |
| Key benefit | Lightweight, inert | High strength |
| Installation note | Easier terminations | Bonding/grounding required |
In-Process and Final Testing
Inline geometry/concentricity checks operate in-line. Final optical tests confirm loss and reflectance. Each order includes a full 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 support traceability and compliance for U.S. programs.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment provides 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 minimizes footprint for risers and conduit. It keeps bend loss low for simple routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs use a support messenger to handle tension. Choose dielectric FRP for electrical isolation or steel messenger when bonding/grounding 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 Fiber draw tower for fast terminations.
Indoor vs 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.
| Design | Best use | Strength element | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting | Overhead spans | Steel wire or FRP | PE |
| Central loose-tube | Higher fiber counts | FRP | LSZH/PE |
| Flat unitube | Low-count, easy strip | FRP/Steel | LSZH/PE |
Equipment Ensuring Quality and Throughput
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment reduce manual handling and increase throughput for patch cord prep.
Our production line integrates automated machines that cut and strip drop patch cords to raise throughput and cut labor variability.
The CLX-BPO2 automated stripper uses PLC + photoelectric control. One cycle is about 1.5 seconds, giving real-world speeds near 20 terminal operations per minute.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH/PVC jackets and trims FRP or steel strength members to precise reserved lengths. Cylinder-driven actuators provide quick, repeatable motion and minimize downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors deliver precise positioning and feedback control. Inline checks update SPC charts so operators can adjust drifts before out-of-control conditions occur.
| Item | Spec | Benefit |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| 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 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 brings industrial-grade stripping and trimming to our line, cutting cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output and standardize terminal quality. The unit cycles in ~1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC/photoelectric control enable precise detection and repeatable actuation. That control keeps strip and stub lengths within tight tolerances.
Line Speed
Typical operation speed is ~1.5 seconds per cycle. This converts to steady throughput under continuous line conditions.
Jacket Strip & Stub 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 fit common termination hardware.
FRP & Steel Member Handling
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Custom tooling are offered for nonstandard sizes to maintain precision.
- Automatic waste ejection and sensor-triggered start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass simplify cell integration.
- Cylinder-driven motion and PLC/photoelectric control boost reliability and reduce maintenance downtime.
| Spec | Rating | Benefit |
|---|---|---|
| Cycle time | ≈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 | 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.
Custom Specs for Your FTTH System
Shanghai Weiye OFC Equipment configures each build to fit 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 match your optics and connector plans.
We Pantone-match sheath colors for fast field ID and consistent asset tagging.
Branding and Print Options
Select LSZH, PVC, or PE jackets to suit route and safety requirements. 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 tailored reels and packaging to fit storage/handling. Choose flat bow-type or self-supporting and FRP or steel members to fit span and isolation requirements.
| Option | Common choice | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and reels |
| Jacket | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Structure | Bow-type / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye schedules runs to your plan and provides docs that detail final specs 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 high-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials/assemblies. These tests recreate field stresses for indoor/outdoor applications.
Full Test Reports for Every Reel
Every fiber optic cable includes 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.
Traceability & Compliance
Lot/batch records link tests to reels/serials so audits and warranty claims are simple to verify. Documentation follows common customer templates to accelerate approvals and receiving inspection.
- Line checks and final inspection prevent field failures and cut warranty events.
- QA packages include spec confirmation and formatted test data for rapid review.
- Continuous test trends inform preventive maintenance and improve long-term reliability.
| Trial | Purpose | Result |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion resistance | Outdoor suitability |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
FTTH Drop Cable Pricing & Cost Drivers
Budgeting for a drop run begins with fiber/jacket selection 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 material, length, and design structure.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber grade, sheath material, and the structural type chosen for deployment.
Self-supporting structures and steel strength elements raise material and labor input. Custom sheath colors/logos/legends add setup time and impact pricing on small runs.
Length/Volume/Customization Impact
Longer reels and higher volume orders lower unit cost. Short runs often carry setup fees and higher per-unit charges.
- Line changeovers and custom tooling extend lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets across phases.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Fiber grade | High impact | Right-size spec to budget |
| Jacket type | Medium | Evaluate LSZH vs PE |
| Length/Volume | Large | Consolidate where possible |
Logistics for the U.S.
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align crews 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 plan capacity to track your milestones and to maintain on-time delivery.
The service team provides updates/tracking so installation teams can plan arrivals. For tight schedules, we reserve contingency capacity to pull in critical-path orders.
Why MOQ Matters
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 choose reel sizes that cut waste and 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-buried run is the best fit for a project.
Deployment Considerations
For aerial runs, Shanghai Weiye OFC Equipment advises self-supporting designs with appropriate members to manage sag/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 matters.
Direct-buried designs need correct burial depth per local codes and moisture-resistant jackets to protect the fiber core long-term.
Indoor Riser/Plenum & ONT
Indoor riser and plenum routes prefer LSZH to meet smoke/flame codes. Flat drop profiles strip cleanly and present controlled stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning exposure, and hardware compatibility. Standardized prep from the production line shortens install time and reduces scrap.
| Scenario | Key feature | Installer note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Underground duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct burial | 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 leads to fewer callbacks, speeds activations, and reliable field performance for your system.
Comprehensive Support & After-Sales
Our team coordinates testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements through approved drawings and pilot builds. We deliver documentation 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 test 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.
- Config control so shipped items match agreed requirements every time.
| Area | Scope | Outcome |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| Testing | Lab + 100% reports | Full traceability |
| Service | Fast replace + RCA | Lower downtime |
Final Thoughts
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
We deliver customized FTTH drop solutions that combine materials with validated manufacturing and lab tests. Every reel includes a 100% test report and documented lab trials to support U.S. field acceptance.
A hardened production line, including CLX-BPO2 prep assets, reduces variability and speeds turnaround. Our equipment and machines 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 support guides scheduling, logistics, and after-sales care so your deployment stays on plan.
Contact Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with lab validation and responsive support.