Fiber-to-the-Home Cable Production: Step-by-Step Manufacturing Process
Did you know: in excess of 70% of new U.S. broadband builds now use fiber networks that need high-precision manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment manages end-to-end Fiber cable sheathing line manufacturing, from sourcing brand fibers like Fujikura or Corning® SMF-28e to final test reports that ensure 100% quality assurance.
Our drop cable designs suit aerial, ducted, and direct-buried installation, with low-smoke zero-halogen (LSZH), PVC, and polyethylene (PE) jacket options and configurations from 1 to 4 cores. We provide 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 high-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 for free replacement on quality issues.
Keep reading to understand how materials plus testing and support combine to lower lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment delivers complete production and laboratory testing for United States projects.
- A range of jacket options and fiber grades support indoor/outdoor environments.
- Automated lines and machines deliver consistent quality and reliable optical performance.
- Fast lead times, low MOQ, and recognized brand fibers help plan procurement reliably.
- Complete reports and after-sales warranty back product reliability and compliance documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment provides tailored drop solutions with complete test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment pairs purpose-built equipment with stringent material control. We offer custom builds and services for residential/MDU deployments. Every order includes 100% quality assurance and full test reports.
Our lab runs high heat, salt spray, and vibration tests to verify durability. Jacket options include LSZH, PVC, and PE. Designs include flat bow-type and self-supporting styles and support brand fibers such as Fujikura® and Corning® SMF-28e.
- Documented line control and production checks for shipments with audit trails.
- Technical support for requirements, pilots, and scaling.
- 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, combining brand fiber choices with rigorous test routines.
Selecting Optical Fiber and Brands
We select fiber ribbon line to 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 meet procurement standards.
Strength Member Options
Strength members employ dielectric FRP or galvanized steel wire. FRP is ideal where non-conductivity is necessary. Steel wire adds tensile strength for long-span aerial runs and bonding/grounding needs.
Jacket Options and Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility and ease of handling, and PE for UV/moisture resistance outdoors. Tight process control of extruder temperature and capstan speed keeps line speed stable and dimensional tolerances.
| Component | FRP | Steel wire |
|---|---|---|
| Use case | Electrical isolation | High-tension aerial runs |
| Advantage | Light, non-corrosive | Very high tensile strength |
| Installation note | Simple terminations | Requires grounding |
Inline and final testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests confirm loss and return loss. Each order includes a full test report and lab results from high-temperature, salt fog, and vibration trials to confirm handling for drop terminations and field use.
Typical lead times are 4–5 days for < 100 km and 7–10 days for < 500 km. Material 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 provides a focused portfolio of 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 flat bow-type drop minimizes footprint for risers and conduit. It reduces bend loss for simple routing in hallways and MDUs.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs include a messenger element to handle tension. Choose FRP (dielectric) for electrical isolation or steel wire when bonding/grounding and extra tensile strength are required.
Strength member and core layouts
We provide both dielectric and metallic strength member configurations to match safety and EMI rules. Center loose tube and flat unitube types balance crush resistance and Fiber draw tower for quick termination.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor durability. Each family is qualified for mechanical and optical quality before shipment.
| Type | Best use | Strength element | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting (aerial) | Aerial spans | FRP/Steel | PE |
| Central loose-tube | Higher fiber counts | FRP | LSZH/PE |
| Unitube flat | Low count, quick strip | FRP/Steel | LSZH or PE |
Production Assets for Speed and Quality
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment reduce manual handling and increase throughput for patch cord prep.
Our production line uses automated machines that cut/strip drop cords to raise throughput and cut labor variability.
The CLX-BPO2 automated stripper runs under PLC and photoelectric control. One cycle is ~1.5 s, giving real-world speeds near 20 terminal operations per minute.
Automated Cut/Strip for Drop Cords
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise reserved lengths. Cylinder-driven actuators deliver fast, repeatable motion and minimize downtime.
PLC & Photoelectric for Precision
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 | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Drive | Pneumatic cylinders | Fast/reliable motion |
| Materials | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic feeders keep the line clean.
- Process control plans document calibration and key parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets without compromising accuracy.
What the CLX-BPO2 Adds
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, reducing cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment deploys 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 and photoelectric control deliver exact detection and repeatable motion. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Line Speed
Typical operation speed is ~1.5 seconds per cycle. This enables steady throughput under normal production conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable strip length from 17.5–35.0 mm. Reserved 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. Custom tooling are available for nonstandard sizes to preserve precision.
- Automatic waste ejection and sensor start reduce idle time.
- Small footprint (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 reduce maintenance downtime.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5–35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0 to 11.0 mm | Meets strength and termination needs |
| Power & size | 50W @ 110–220V; 40×18×18 cm | Easy integration into existing equipment |
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 sacrificing quality.
Custom Specs for Your FTTH System
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 receive ready-to-install products.
Choose 1 to 4 cores with single-mode or multimode fiber. Options include OS1/OS2 plus OM2–OM4 along with G.652D/G.657 variants to match your optics and connector plans.
We match sheath colors to Pantone codes for fast field ID and consistent asset tagging.
Jackets, Legends & Branding
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom print legends and logos support inventory and warranty tracking.
Lengths, Packaging & Special Builds
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 meet span and isolation needs.
| Option | 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 supplier, Shanghai Weiye schedules runs to your plan and provides docs that lists final specifications for straightforward QA on site.
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 conducts high-temperature exposure, salt fog corrosion, and mechanical vibration 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 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.
Traceability and 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.
- Line checks and final inspection reduce field failures and lower warranty events.
- Quality packages include specifications confirmation and formatted test data for rapid review.
- Continuous test trends inform preventive maintenance and raise long-term reliability.
| Trial | Purpose | Outcome |
|---|---|---|
| Heat exposure | Material stability | Pass at target temperature |
| Salt-fog | Corrosion resistance | Qualified for outdoor use |
| Mechanical vibration | Resistance to vibration | Improved field reliability |
Pricing and cost drivers for FTTH drop cable
Budget planning for a drop 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 (G.652/G.657/OM2–OM4), jacket material, length, and structural design.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber grade, sheath material, and the structural type chosen for deployment.
Self-supporting structures and steel members raise material and labor input. Custom colors, logos, and print legends add setup time and impact pricing on small runs.
Order length, volume, and customization impact on price
Longer put-ups and larger volumes lower unit cost. Small quantities often carry setup fees and higher per-unit charges.
- Line changeovers and custom tooling extend lead time and add cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Optical grade | High impact | Balance spec vs. budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Order length / volume | High impact | Consolidate where possible |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align staffing and sites. Predictable windows reduce downtime and help control cost 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 schedule line capacity to track your milestones and to maintain on-time delivery.
The service team issues production updates and tracking so installation teams know when reels arrive. For tight schedules, we hold contingency capacity to accelerate critical-path orders.
Minimum order quantity and why it matters
The MOQ is one kilometer. This reflects setup needs such as wire and jacket die adjustments that consume start-up material and scrap.
We review your length and staging plans to choose reel sizes that cut waste and handling. Staggered batches can balance inventory with more frequent small-site deliveries.
Where and How to Deploy
On-site conditions determine whether a self-supporting aerial, duct pull, or direct burial is the best fit for a project.
Aerial, duct, and direct-buried deployment considerations
For aerial runs, Shanghai Weiye OFC Equipment advises self-supporting designs with correct strength members to manage sag/tension for long-term reliability.
Duct installations perform best with low-friction jackets and crush-resistant builds 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 fiber core long-term.
Indoor Distribution and ONT
Indoor riser and plenum routes favor LSZH jackets to meet smoke/flame codes. Flat drop profiles strip cleanly and present controlled strength 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 reduces install time and reduces scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Duct | Low-friction, crush-resistant | 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 penetrations |
Our approach ensures a consistent install experience across indoor/outdoor transitions. That leads to fewer callbacks, faster 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 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 help QA acceptance.
- 24/7 availability for status updates and technical guidance.
- Warranty includes free replacement for confirmed quality issues.
- Schedule coordination for expedites and urgent changes.
- Config control so shipped items match agreed requirements every time.
| Area | Scope | Outcome |
|---|---|---|
| Tech/Eng | Specs + pilots | Fewer field issues |
| Testing | Lab + 100% reports | Full traceability |
| Service | Fast replace + RCA | Minimized downtime |
Wrap-Up
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, cuts variability and shortens turnaround. Our equipment and machines standardize strip/stub lengths so installers get consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance design and cost to extend service life. Dedicated support covers scheduling/logistics/after-sales so your deployment stays on plan.
Contact Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with laboratory validation and responsive service.