Fiber-to-the-Home Cable Production: How the Manufacturing Process Works
Surprising fact: in excess of 70% of new U.S. broadband builds now rely on fiber networks that require tight manufacturing control to meet performance goals.
Shanghai Weiye OFC Equipment manages full-cycle FTTH cable production line manufacturing, from selecting brand fibers like Fujikura or Corning® SMF-28e to complete test reports that guarantee full quality assurance.
Our FTTH drop designs are built for aerial, ducted, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and PE jacket options and arrangements from 1 to 4 cores. We offer single-mode OS1/OS2 and multimode OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone sheath colors, and logo printing.
Automated machines and high-precision equipment keep line speed steady and keep repeatability high. Typical lead times run 4–5 days for orders < 100 km and seven to ten days for < 500 km, with an MOQ of 1 km and warranty covering free replacement for confirmed quality issues.
Keep reading to learn how materials, testing, and support combine to lower lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment delivers end-to-end manufacturing and lab testing for U.S. deployments.
- Multiple jacket choices and fiber grades support varied installation environments.
- Automated production lines deliver consistent quality and reliable optical performance.
- Quick lead times, low minimums, and recognized brand fibers keep procurement predictable.
- Complete reports and after-sales warranty back product reliability and documentation needs.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment provides tailored drop solutions with complete test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment pairs specialized equipment with tight material control. We provide customized service and products for single-family and MDU rollouts. Every order includes full QA coverage and full test reports.
Our lab performs high heat, salt spray, 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 in-process checks for fully auditable shipments.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixtures and calibration reduce variability so every cable matches operator specs.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, combining brand fiber choices with rigorous test routines.
Selecting Optical Fiber and Brands
We select fiber secondary coating 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 available to satisfy sourcing standards.
Strength Member Options
Strength members use dielectric FRP or galvanized steel wire. FRP is preferred where non-conductive runs are required. Steel wire adds tensile strength for long-span aerial runs and bonding/grounding needs.
Jacket extrusion and process control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility and ease of handling, and PE for outdoor UV and moisture resistance. Tight process control of extruder temperature and capstan speed keeps line speed stable and dimensional tolerances.
| Component | FRP | Metallic Steel |
|---|---|---|
| Use case | Non-conductive runs | Aerial spans, high tensile |
| Advantage | Lightweight, inert | Very high tensile strength |
| Installer note | Easier terminations | Bonding/grounding required |
In-Process and Final Testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests verify loss and return loss. Each order ships with a full test report and lab results from high heat, salt-spray, and vibration trials to confirm handling for drop terminations and field use.
Typical lead times are 4–5 days for < 100 km and under 500 km in 7–10 days. Lot records and FAI approvals provide traceability and compliance for U.S. projects.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment offers a compact portfolio of FTTH drop designs that suit both tight indoor routes and exposed aerial spans. Each option combines tested materials with field-termination geometry and consistent optical performance.
The bow-type flat drop cable minimizes footprint for risers/ducts. It keeps bend loss low for easy routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs include a support messenger to carry tensile loads. Choose dielectric FRP for non-conductive runs or steel wire 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 unitube flat types balance crush resistance and fiber secondary coating line for fast terminations.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor UV and moisture resilience. Each series is validated for mechanical/optical performance before shipment.
| Design | Application | Strength element | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | Dielectric FRP | LSZH |
| Self-supporting (aerial) | Aerial spans | FRP/Steel | Polyethylene |
| Central loose-tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Flat unitube | Low count, quick strip | FRP or steel | LSZH/PE |
Production line equipment that ensures quality and speed
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for patch cord prep.
Our production line integrates automated machines that cut and strip drop patch cords to increase output and reduce operator variability.
The CLX-BPO2 automated stripper uses PLC + photoelectric control. One cycle is ~1.5 s, giving ~20 terminals per minute in production.
Auto Cut & Strip Capabilities
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise stub lengths. Pneumatic cylinder actuators provide quick, repeatable motion and low downtime.
PLC/photoelectric control for precision and repeatability
PLC logic and 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 | Auto-strip, ~1.5 s cycle | High 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 |
- Automated waste ejection and ergonomic loading keep the line clean.
- PCPs document calibration and key parameters.
- Integrated assets and trained operators support FTTH volume targets without sacrificing accuracy.
CLX-BPO2 auto-stripping machine capabilities in 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 raise output and standardize prep quality. The unit runs at an approximate cycle time of 1.5 seconds, producing around 20 preps per minute in production.
PLC/photoelectric control deliver exact detection and repeatable motion. That control keeps strip and stub lengths within tight tolerances.
Throughput & Cycle Time
Typical operation speed is 1.5s per cycle. This translates to steady throughput under normal production conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 handles LSZH/PVC 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.
Handling FRP and steel wire strength members
The machine cleanly cuts FRP and steel wire strength elements while protecting adjacent fibers. Customized cutters are offered for nonstandard sizes to preserve precision.
- Auto-eject scrap and sensor start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight ease integration into workcells.
- Cylinder-driven motion and closed-loop control boost reliability and reduce maintenance downtime.
| Spec | Value | Benefit |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | Supports high-volume runs |
| Strip lengths (A) | 17.5–35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0 to 11.0 mm | Meets strength and termination needs |
| Power/Size | 110–220V, 50W; 40×18×18 cm | Easy integration into existing equipment |
Using this machine, Shanghai Weiye OFC Equipment standardizes prep so field teams get drop parts install-ready. The CLX-BPO2 supports our lines in meeting volume targets without compromising quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures every order to fit your network requirements and simplify deployment. We combine focused options with predictable schedules so your teams receive ready-to-install products.
Choose 1–4 core designs 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 quick field identification and consistent asset tagging.
Jacket materials, print legends, and 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 put-ups are 1 km, 2 km, and 4 km with custom reels and packaging to fit storage/handling. Choose bow-type flat or self-supporting designs and FRP or steel members to meet span and isolation needs.
| Choice | Typical | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and reels |
| Jacket | LSZH / PE / PVC | Indoor/Outdoor fit |
| Structure | Flat bow / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye schedules runs to your plan and provides docs that detail final specs for straightforward QA on site.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment builds checkpoints into production so every item ships with recorded acceptance data.
Environmental and Mechanical Tests
Our lab runs high-temperature exposure, salt spray corrosion, and vibration tests to qualify materials/assemblies. These tests simulate field stresses for indoor/outdoor applications.
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 QC 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.
- In-line checks plus final inspection reduce field failures and cut warranty events.
- Quality packages include specifications confirmation and formatted data for quick review.
- Ongoing trend analysis inform preventive maintenance and raise long-term reliability.
| Test | Purpose | Outcome |
|---|---|---|
| High-temperature | Material stability | Pass at target temperature |
| Salt spray | Corrosion resistance | Outdoor suitability |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
FTTH Drop Cable Pricing & Cost Drivers
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, jacket material, reel length, and structural design.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber grade, sheath material, and the chosen structure for deployment.
Self-supporting designs and steel members raise material and labor input. Custom sheath colors/logos/legends add setup and influence price for short runs.
How Volume & Options Affect Cost
Longer reels and higher volume orders lower unit cost. Short runs 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.
- Framework agreements and indexed pricing stabilize budgets across phases.
| Driver | Price impact | Recommendation |
|---|---|---|
| Fiber grade | Large | Balance spec vs. budget |
| Jacket type | Medium | Compare LSZH vs. PE for total cost |
| Length/Volume | Large | Consolidate runs to cut unit cost |
Logistics for the U.S.
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align staffing and sites. Predictable schedules reduce 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 match your rollout milestones and to maintain on-time delivery.
The service team issues production updates and tracking so installation teams can plan arrivals. 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 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. Batch releases can balance inventory holding with more frequent small-site deliveries.
Installation readiness and application scenarios
Site conditions determine whether a self-supporting span, ducted pull, or direct-buried run is the best fit for a project.
Aerial vs Duct vs Direct-Buried
For aerial runs, Shanghai Weiye OFC Equipment advises self-supporting designs with correct strength members to control sag and tension for long-term reliability.
Duct installations work 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 require proper depth control per local codes and moisture-resistant jackets to protect the fiber core long-term.
Indoor riser/plenum distribution and ONT termination
Indoor riser/plenum routes favor LSZH jackets to meet flame and smoke rules. Flat drop profiles strip cleanly and present controlled stubs for quick ONT termination.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware fit. Standardized prep from the production line shortens install time and minimizes scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow local depth and warning tape rules |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That reduces callbacks, faster activations, and stable field performance for your system.
Comprehensive Support & After-Sales
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 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 help 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 urgent changes or acceleration requests.
- Config control so shipped items match agreed requirements every time.
| Area | Scope | Benefit |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| Testing | Lab trials & 100% test reports | Full traceability |
| After-sales | Rapid replacement & root-cause | Minimized downtime |
Wrap-Up
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
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 robust production line, including CLX-BPO2 prep assets, cuts variability and shortens turnaround. Our equipment set standardize strip/stub lengths so installers see consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance performance and cost to extend service life. Dedicated support guides scheduling, logistics, and after-sales care so your deployment remains on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every fiber optic and optic cable shipment with lab validation and responsive service.