Fiber-to-the-Home Cable Production: How the Manufacturing Process Works
Did you know: more than 70% of new U.S. broadband builds now use fiber networks that require high-precision manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment handles complete FTTH cable production line manufacturing, from choosing brand fibers like Fujikura® or Corning SMF-28e to final test reports that guarantee full quality assurance.
Our FTTH drop designs are built for overhead, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), PVC, and polyethylene (PE) jacket options and arrangements from 1–4 cores. We supply single-mode OS1/OS2 and OM2–OM4 grades plus G.652D and G.657 variants, Pantone sheath colors, and logo printing.
Automation and precision equipment stabilize line speed and keep repeatability high. Typical lead times are four to five days for orders under 100 km and 7–10 days for < 500 km, with an min. order of 1 km and warranty for free replacement on quality issues.
Read on 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 complete production and laboratory testing for U.S. deployments.
- A range of jacket options and optical grades cover different install environments.
- Automated lines and machines provide stable quality and reliable optical performance.
- Fast lead times, low minimums, and recognized brand fibers support reliable procurement planning.
- Comprehensive test reports and 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 customized drop cables with full test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment pairs specialized equipment with stringent material control. We offer customized service and products for residential/MDU deployments. Every order includes full QA coverage and complete test reports.
Our lab performs high heat, salt-fog, and vibration tests to verify durability. Jacket options include LSZH, PVC, and PE. Designs include flat bow-type and figure-8/self-supporting styles and use brand fibers such as Fujikura® and Corning® SMF-28e.
- Documented line control and in-process checks for auditable shipments.
- 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 matched to network specs, pairing brand fiber choices with disciplined test flows.
Optical fiber selection and brand options
We select fiber draw tower to bend radius, attenuation, 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.
Integrating Strength Members
Strength members employ dielectric FRP or galvanized steel wire. FRP is ideal where non-conductivity is necessary. Steel wire provides tensile strength for long-span aerial runs and bonding/grounding needs.
Extrusion & Process Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility, and PE for outdoor UV and moisture resistance. Tight process control of temperature and capstan ratios keeps line speed stable and critical dimensions.
| Member | FRP | Metallic Steel |
|---|---|---|
| Use case | Non-conductive runs | Aerial spans, high tensile |
| Key benefit | 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 reflectance. Each order ships with a 100% test report and lab results from high heat, salt fog, and vibration tests 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 support traceability and compliance for U.S. programs.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment provides a compact portfolio of drop designs that suit both 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 keeps a small 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 and extra tensile strength are required.
Strength member and core layouts
We provide both 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 quick termination.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use 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, MDUs | FRP (dielectric) | LSZH |
| Self-supporting | Overhead spans | Steel wire or FRP | PE |
| Center loose tube | Higher-count builds | FRP | LSZH or PE |
| Unitube flat | 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 raise throughput and cut labor variability.
The CLX-BPO2 auto-stripping machine runs under PLC and photoelectric control. One cycle is ~1.5 s, giving real-world speeds near 20 terminal operations per minute.
Auto Cut & Strip Capabilities
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise reserved lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and minimize downtime.
PLC & Photoelectric for Precision
PLC logic and photoelectric sensors deliver precise positioning and closed-loop control. Inline checks update SPC charts so operators can correct trends before out-of-control conditions occur.
| Item | Spec | Benefit |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Materials | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Consistent quality, lower 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 sacrificing accuracy.
What the CLX-BPO2 Adds
The CLX-BPO2 provides industrial-grade strip/trim to our line, reducing cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output and standardize prep quality. The unit runs at an approximate cycle time of 1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC and photoelectric control deliver exact detection and repeatable actuation. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Line Speed
Typical operation speed is 1.5s per cycle. This converts 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 stubs are adjustable from 7.0–11.0 mm to fit common termination hardware.
Cutting FRP/Steel Members
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Custom tooling are offered for non-standard cross-sections to preserve precision.
- Automatic waste ejection and sensor start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg weight simplify cell integration.
- Pneumatic cylinders and PLC/photoelectric control improve line reliability and reduce maintenance downtime.
| Specification | Rating | Why it matters |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5–35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0–11.0 mm | Supports termination strength |
| 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 sacrificing quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures each build to fit your network requirements and simplify field rollout. We combine focused options with predictable schedules 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 and G.657 variants to match your optics and connector plans.
We Pantone-match sheath colors for fast field ID and consistent asset tags.
Branding and Print Options
Select LSZH, PVC, or PE jackets to suit route and safety requirements. Custom legends/logos support inventory and warranty tracking.
Length options, packaging, and special structures
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 fit span and isolation requirements.
| Option | Common choice | Advantage |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Less staging, easier reels |
| Sheath | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Design | Bow-type / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and delivers documentation that lists final specifications for straightforward QA on site.
Quality assurance, testing, and documentation
Shanghai Weiye OFC Equipment builds checkpoints into production so every item ships with recorded acceptance data.
High-temperature, salt spray, and vibration laboratory testing
Our lab conducts elevated-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials and 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 logs attenuation, return loss, and geometry where applicable. Final QC gates prevent nonconforming shipments before they leave the factory.
Traceability & Compliance
Batch records tie test data to reels and serials so audits and warranty claims are simple to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- Line checks and final inspection reduce field failures and cut warranty events.
- QA packages include spec confirmation and formatted data for rapid review.
- Ongoing trend analysis inform preventive maintenance and improve long-term reliability.
| Test | Why | Result |
|---|---|---|
| Heat exposure | Material stability | Validated heat endurance |
| Salt spray | Corrosion resistance | Qualified for outdoor use |
| Mechanical vibration | Resistance to vibration | Improved field reliability |
Cost Drivers and Pricing
Budget planning for a drop begins with fiber/jacket selection and is shaped 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 structural design.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber grade, jacket material, and the structural type chosen for deployment.
Self-supporting designs and steel strength elements raise material and labor input. Custom colors, logos, and print legends add setup time and influence price for short runs.
How Volume & Options Affect Cost
Longer put-ups and larger volumes lower unit cost. Small quantities 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.
- Frameworks and indexed pricing stabilize budgets over phases.
| Factor | Price impact | Recommendation |
|---|---|---|
| Fiber grade | High impact | Balance spec vs. budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Length/Volume | Large | Consolidate runs to cut unit cost |
Lead times, MOQ, and delivery for the United States
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews and sites. Predictable windows reduce downtime and control costs when a rollout is underway.
Production Windows & Capacity
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 provides updates/tracking so installation teams know when reels arrive. For compressed 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 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.
Installation readiness and application scenarios
On-site conditions determine whether a self-supporting span, ducted pull, or direct-buried run is the right choice for a project.
Deployment Considerations
For aerial runs, Shanghai Weiye OFC Equipment recommends 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 does not damage fibers. 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-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 strength stubs for quick ONT termination.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware compatibility. Standardized line prep reduces install time and minimizes scrap.
| Deployment | Key feature | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct-buried | 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 reduces callbacks, speeds activations, and reliable field performance for your system.
Comprehensive Support & After-Sales
Our team coordinates testing, scheduling, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements through approved drawings and pre-production 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 support QA acceptance.
- Round-the-clock availability for status and technical support.
- 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 specs consistently.
| Support area | Scope | Outcome |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Reduced field issues |
| Testing | Lab trials & 100% test reports | Traceable quality |
| After-sales | Fast replace + RCA | 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 combine materials with validated manufacturing and lab tests. Every reel ships with 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 shortens turnaround. Our equipment set 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.
Contact Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with laboratory validation and responsive support.