Fiber-to-the-Home Cable Production: Step-by-Step Manufacturing Process
Quick fact: more than 70% of new U.S. broadband builds now depend on fiber networks that require high-precision manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment manages full-cycle compact fiber unit manufacturing, from choosing brand fibers like Fujikura® or Corning SMF-28e to complete test reports that guarantee full quality assurance.
Our drop cable designs fit overhead, underground, and direct burial installation, with LSZH, PVC, and PE jacket options and arrangements from 1–4 cores. We provide OS1/OS2 and multimode OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone sheath colors, and custom logo printing.
Automation and precision equipment keep line speed steady and repeatability high. Typical lead times are 4–5 days for orders under 100 km and seven to ten days under 500 km, with an MOQ of 1 km and warranty covering free replacement for confirmed quality issues.
Continue to see how materials, testing, 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.
- A range of jacket options and fiber grades fit indoor/outdoor environments.
- Automated lines and machines provide stable quality and reliable optical performance.
- Quick lead times, low MOQ, and brand fiber options help plan procurement reliably.
- Comprehensive test reports and after-sales warranty back product reliability and 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 offer custom builds and services for residential/MDU deployments. Every order comes with full QA coverage and full test reports.
Our lab conducts high-temperature, salt-fog, and vibration testing to verify durability. Jacket options include LSZH, PVC, and PE. Designs cover bow-type flat and self-supporting styles and support brand fibers such as Fujikura and Corning SMF-28e.
- Controlled production lines and production checks for shipments with audit trails.
- Engineering support for requirements, pilots, and scaling.
- Modern fixturing and calibration reduce variability so every cable matches operator specs.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with rigorous test routines.
Optical fiber selection and brand options
We align FTTH cable production line to bend radius, loss, and deployment type. 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 available to meet procurement standards.
Integrating Strength Members
Strength members use FRP (dielectric) or galvanized steel wire. FRP is ideal where non-conductivity is necessary. Steel wire provides tensile strength for longer aerial spans and grounding needs.
Extrusion & Process Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility and ease of handling, and PE for outdoor UV and moisture resistance. Closed-loop control of extruder temperature and capstan speed keeps line speed stable and critical dimensions.
| Component | FRP | Steel wire |
|---|---|---|
| Primary use | Non-conductive runs | Aerial spans, high tensile |
| Advantage | Light, non-corrosive | Very high tensile strength |
| Installation note | Simple terminations | Requires grounding |
Testing & Verification
Inline geometry/concentricity checks run during manufacturing. Final optical tests confirm loss and return loss. Each order includes 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 under 100 km in 4–5 days and under 500 km in 7–10 days. Material lot records and FAI approvals provide traceability and compliance for U.S. programs.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment provides a compact portfolio of 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 bow-type flat drop cable minimizes footprint for risers and conduit. It reduces bend loss for easy routing in hallways and MDUs.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs include a messenger element to handle tension. Choose dielectric FRP for electrical isolation or steel wire when bonding 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 flat unitube types balance crush resistance and fiber ribbone line for quick termination.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor durability. Each series is qualified for mechanical and optical quality before shipment.
| Type | Best use | Strength element | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting | Overhead spans | FRP/Steel | PE |
| Central loose-tube | Higher-count builds | FRP | LSZH or PE |
| Flat unitube | Low count, quick 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 patch cord prep.
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 ~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 stub lengths. Cylinder-driven actuators deliver fast, repeatable motion and low downtime.
Closed-Loop Control for Repeatability
PLC logic + photoelectric sensors deliver precise positioning and closed-loop control. Inline checks feed control charts so operators can adjust drifts before defects grow.
| Item | Spec | Result |
|---|---|---|
| CLX-BPO2 | 1.5s cycle, auto-strip | ~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 | Stable quality, reduced 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.
What the CLX-BPO2 Adds
The CLX-BPO2 provides industrial-grade strip/trim to our line, reducing cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment uses 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/photoelectric control enable precise detection and repeatable actuation. 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 translates to steady throughput under normal production conditions.
Supported jacket and reserved strength lengths
The CLX-BPO2 handles LSZH/PVC 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.
FRP & Steel Member Handling
The machine cuts FRP/steel strength elements cleanly while protecting adjacent fibers. Custom tooling are offered 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 PLC/photoelectric control boost reliability and reduce maintenance downtime.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | High throughput for production 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 | 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 helps our production lines meet volume goals without sacrificing quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures each build 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 to 4 cores with SM or MM fiber. Options include OS1, OS2, and OM2–OM4 plus 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 tags.
Jacket materials, print legends, and branding
Select LSZH/PVC/PE jackets based on route and safety rules. Custom legends/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 bow-type flat or self-supporting designs and FRP or steel members to meet span and isolation needs.
| Choice | Typical | Benefit |
|---|---|---|
| Reel length | 1, 2, or 4 km | Simpler staging and reels |
| Sheath | LSZH / PE / PVC | Indoor/Outdoor fit |
| Design | Bow-type / Self-supporting | Flexible routing/span |
As a supplier, Shanghai Weiye aligns runs to your schedule and provides docs that lists final specifications for easy on-site QA.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment builds checkpoints into production so every item has recorded acceptance data at ship.
High-temperature, salt spray, and vibration laboratory testing
Our lab conducts high-temperature exposure, salt fog corrosion, and vibration tests to qualify materials/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 prevent nonconforming shipments before they leave the factory.
Traceability & Compliance
Lot/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.
- Line checks and final inspection reduce field failures and cut warranty events.
- Quality packages include specifications confirmation and formatted data for rapid review.
- Ongoing trend analysis inform preventive maintenance and raise long-term reliability.
| Trial | Purpose | Outcome |
|---|---|---|
| Heat exposure | Material stability | Validated heat endurance |
| Salt spray | Corrosion robustness | Outdoor suitability |
| Mechanical vibration | Resistance to vibration | 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 vary widely—from about $30 to $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, sheath material, and the chosen structure for deployment.
Self-supporting structures and steel members increase material/labor. Custom colors, logos, and print legends add setup and influence price for short runs.
How Volume & Options Affect Cost
Longer put-ups and larger volumes reduce unit cost. Short runs often include setup charges and higher per-unit charges.
- Line changeovers and custom tooling increase lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets across phases.
| Driver | Effect on price | Recommendation |
|---|---|---|
| Fiber grade | High impact | Balance spec vs. budget |
| Sheath material | Medium impact | Evaluate LSZH vs PE |
| Length/Volume | Large | Consolidate where possible |
Lead times, MOQ, and delivery for the United States
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align staffing and sites. Predictable windows cut downtime and help control cost when a rollout is underway.
Production Windows & Capacity
Typical production windows are 4–5 days for < 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 know when reels arrive. For tight schedules, we hold contingency capacity to accelerate critical-path orders.
Why MOQ Matters
The MOQ is 1 km. This reflects line setup such as wire/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 dictate whether a self-supporting aerial, 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 advises self-supporting designs with appropriate members to control sag and tension for long-term reliability.
Duct installations perform 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 require proper depth control per local codes and moisture barriers to protect the optic core over time.
Indoor Riser/Plenum & ONT
Indoor riser and plenum routes prefer LSZH to meet flame and smoke rules. Flat drop profiles strip clean and present controlled strength stubs for quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding requirements, lightning exposure, and hardware fit. Standardized prep from the production line reduces install time and minimizes scrap.
| Deployment | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Duct | Low-friction, crush-resistant | Use pull tape and proper lubricant |
| Direct burial | PE jacket, moisture barrier | Follow local depth and warning tape rules |
| Interior | LSZH jacket, tight bend support | Maintain bend radius at penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That reduces callbacks, faster activations, and stable field performance for your system.
Support from Spec to Service
Our team coordinates testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements through approved drawings and pilot builds. We provide doc templates and clear installation 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 help QA acceptance.
- 24/7 availability for status and technical support.
- Warranty includes free replacement for confirmed quality issues.
- Coordination of line schedules for urgent changes or acceleration requests.
- Config control so shipped items match agreed requirements every time.
| Area | Scope | Outcome |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Reduced field issues |
| QA/Testing | Lab + 100% 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 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 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 laboratory validation and responsive service.
