Fiber-to-the-Home Cable Production: Step-by-Step Manufacturing Process
Quick fact: in excess of 70% of new broadband deployments in the U.S. now use fiber networks that demand precise manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment manages complete compact fiber unit manufacturing, from choosing brand fibers like Fujikura or Corning SMF-28e to complete test reports that ensure 100% quality assurance.
Our FTTH drop designs are built for overhead, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), PVC, and PE jacket options and core counts from 1–4 cores. We provide single-mode OS1/OS2 and OM2–OM4 grades plus ITU-T 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 repeatability high. Typical lead times run 4–5 days for orders under 100 km and 7–10 days for < 500 km, with an MOQ of 1 km and warranty covering free replacement for confirmed quality issues.
Read on to understand how materials plus testing and support work together to reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment delivers complete production and laboratory testing for United States projects.
- A range of jacket options and optical grades support varied installation environments.
- Automated lines and machines deliver stable quality and reliable optical performance.
- Quick 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.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment provides customized drop cables with complete test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment combines purpose-built equipment with stringent material control. We provide custom builds and services for residential/MDU deployments. Every order comes with 100% quality assurance and complete test reports.
Our lab performs high heat, salt spray, and vibration testing to validate durability. Jacket options cover LSZH, PVC, and PE. Designs offer flat bow-type and figure-8/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.
- Technical support for specs, trials, and ramp to volume.
- Modern fixtures and calibration minimize variation so every cable meets carrier standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, combining brand fiber choices with disciplined test flows.
Selecting Optical Fiber and Brands
We select FTTH cable production line to bend radius, attenuation, 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 metallic steel wire. FRP is preferred where non-conductivity is necessary. Steel wire adds tensile strength for longer aerial spans and grounding needs.
Jacket Options and Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility, and PE for UV/moisture resistance outdoors. Closed-loop control of temperature and capstan ratios stabilizes line speed and critical dimensions.
| Member | Dielectric FRP | Metallic Steel |
|---|---|---|
| Use case | Electrical isolation | Aerial spans, high tensile |
| Advantage | Lightweight, inert | High strength |
| Installation 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 includes a 100% test report and lab results from high heat, 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 FAI approvals provide traceability and compliance for U.S. projects.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment offers a compact 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 bow-type flat drop cable keeps a small footprint for risers and conduit. It reduces bend loss 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 electrical isolation or steel messenger when bonding and extra tensile strength are required.
Strength member and core layouts
We provide dielectric and metallic strength member configurations to meet safety/EMI requirements. Center loose tube and flat unitube types balance crush resistance and fiber secondary coating line for quick termination.
Indoor vs Outdoor Jackets
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.
| Design | Application | Strength element | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | Dielectric FRP | LSZH |
| Self-supporting (aerial) | Aerial spans | Steel wire or FRP | Polyethylene |
| Central loose-tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Unitube flat | Low count, quick strip | FRP/Steel | LSZH/PE |
Production Assets for Speed and Quality
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and increase throughput for patch cord prep.
Our production line uses automated machines that cut and strip drop patch cords to increase output 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.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH and 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 give exact positioning and feedback control. Inline checks feed control charts so operators can correct trends before out-of-control conditions occur.
| Feature | Capability | Benefit |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Material handling | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Process control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic feeders keep the line clean.
- PCPs document calibration and key parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without compromising accuracy.
CLX-BPO2 Capabilities on Our Line
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 cycles in ~1.5 seconds, producing around 20 preps per minute in production.
PLC/photoelectric control enable precise detection and repeatable actuation. That control keeps strip and stub lengths within tight tolerances.
Throughput & Cycle Time
Typical operation speed is ~1.5 seconds per cycle. This translates to steady throughput under normal production conditions.
Jacket Strip & Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable strip length from 17.5 to 35.0 mm. Reserved strength member 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 neighboring fibers. Customized cutters are available for nonstandard sizes to preserve precision.
- Auto-eject scrap and sensor-triggered start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass simplify cell integration.
- Pneumatic cylinders and PLC/photoelectric control boost reliability and reduce maintenance downtime.
| Specification | Rating | Benefit |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5 to 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 helps our production lines meet volume goals without compromising quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures every order to fit your network requirements and simplify deployment. 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, 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 fast field ID and consistent asset tagging.
Branding and Print Options
Select LSZH, PVC, or 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.
| Option | Typical | Benefit |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and reels |
| Jacket | LSZH, PE, PVC | Indoor/Outdoor fit |
| Structure | Flat bow / Self-supporting | Flexible routing/span |
As a supplier, Shanghai Weiye schedules runs to your plan and delivers documentation that detail final specs for easy on-site QA.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item ships with recorded acceptance data.
Environmental and Mechanical Tests
Our lab runs elevated-temperature exposure, salt fog corrosion, and vibration tests to qualify materials/assemblies. These tests recreate field stresses for indoor and outdoor use.
Per-Reel 100% Reports
Every fiber optic cable includes a 100% test report that logs attenuation, return loss, and geometry where applicable. Final inspection 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 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 improve long-term reliability.
| Trial | Purpose | Result |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt spray | Corrosion resistance | Qualified for outdoor use |
| Vibration | Mechanical robustness | Reduced field failures |
Cost Drivers and Pricing
Budget planning for a drop begins with fiber/jacket selection and is shaped 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, 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 increase lead time and add cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets over phases.
| Factor | Effect on price | Guidance |
|---|---|---|
| Fiber grade | Large | Right-size spec to budget |
| Jacket type | Medium impact | 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 control costs when a rollout is underway.
Typical production windows and capacity planning
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 can plan arrivals. For tight schedules, we reserve contingency capacity to accelerate critical-path orders.
Minimum order quantity and why it matters
The MOQ is 1 km. This reflects line setup such as wire and jacket 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. Staggered batches can balance inventory with more frequent small-site deliveries.
Where and How to Deploy
Site conditions dictate 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 work best with low-friction jackets and crush-resistant builds so pulling does not damage fibers. 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 optic core over time.
Indoor Riser/Plenum & 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 quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware fit. Standardized line prep reduces install time and minimizes scrap.
| Deployment | 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-buried | PE jacket, moisture barrier | Follow depth/warning tape codes |
| Interior | LSZH with tight-bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That reduces 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 avoid surprises in deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements capture through approved drawings and pre-production builds. We provide doc 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 test reports and traceability to support QA acceptance.
- Round-the-clock availability for status updates and technical guidance.
- Warranty with free replacement if any quality problems are confirmed.
- Coordination of line schedules for expedites and urgent changes.
- Config control so shipped items match agreed requirements every time.
| Area | Scope | Benefit |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Reduced field issues |
| QA/Testing | Lab trials & 100% test 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 pair material choices with validated manufacturing and lab testing. Every reel ships with a 100% test report and documented lab trials to support U.S. field acceptance.
A robust 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 to jacket, printing, and packaging, we balance performance and cost to maximize 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 fiber optic and optic cable shipment with laboratory validation and responsive support.