Fiber-to-the-Home Cable Production: How the Manufacturing Process Works
Quick fact: over seventy percent of new broadband deployments in the U.S. now use fiber networks that require tight manufacturing control to hit performance targets.
Shanghai Weiye OFC Equipment handles end-to-end compact fiber unit manufacturing, from sourcing brand fibers like Fujikura or Corning SMF-28e to comprehensive test documentation that deliver 100% QA.
Our drop designs fit overhead, ducted, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and polyethylene (PE) jacket options and core counts from 1–4 cores. We offer OS1/OS2 and multimode OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone sheath colors, and logo printing.
Automation and high-precision equipment keep line speed steady and maximize repeatability. Typical lead times run 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 covering free replacement for confirmed quality issues.
Read on to see how materials plus testing and support help reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment provides full manufacturing with lab validation for U.S. deployments.
- Multiple jacket choices and optical grades fit varied installation environments.
- Automated production lines provide stable quality and reliable optical performance.
- Fast lead times, low minimums, and brand fiber options help plan procurement reliably.
- Complete reports and after-sales warranty back product reliability and documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment provides customized drop cables with full 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 runs high-temperature, salt-fog, and vibration tests to validate durability. Jacket options include LSZH, PVC, and PE. Designs cover flat bow-type and figure-8/self-supporting styles and use brand fibers such as Fujikura and Corning SMF-28e.
- Controlled production lines and production checks for auditable shipments.
- Engineering support for requirements, pilots, and scaling.
- Modern fixturing and calibration reduce variability so every cable meets operator standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, combining brand fiber choices with strict test routines.
Selecting Optical Fiber and Brands
We select fiber draw tower 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 available to satisfy sourcing standards.
Integrating Strength Members
Strength members employ FRP (dielectric) or metallic steel wire. FRP is ideal where non-conductivity is necessary. Steel wire adds tensile strength for long-span aerial runs and grounding needs.
Jacket Options and Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility, and PE for outdoor UV and moisture resistance. Tight process control of extruder temperature and capstan speed stabilizes line speed and dimensional tolerances.
| Member | FRP | Steel wire |
|---|---|---|
| Use case | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Lightweight, inert | High strength |
| Installer note | Simple terminations | Bonding/grounding required |
Testing & Verification
Inline geometry and concentricity checks operate in-line. Final optical tests verify loss and return loss. Each order ships with a full 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 under 500 km in 7–10 days. Lot records and first-article approvals provide traceability and compliance for U.S. programs.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment offers a focused 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 stable optical performance.
The bow-type flat drop cable minimizes footprint for risers and conduit. It reduces bend loss for easy routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs use a support messenger to carry tensile loads. Choose dielectric FRP for non-conductive runs 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. Center loose tube and flat unitube types balance crush resistance and fiber secondary coating line for fast terminations.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each family is qualified for mechanical/optical performance before shipment.
| Design | Application | Strength member | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | Dielectric FRP | LSZH |
| Self-supporting | Overhead spans | Steel wire or FRP | PE |
| Central loose-tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Flat unitube | Low count, quick strip | FRP or steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and boost throughput for drop patch preparation.
Our production line integrates automated machines that cut/strip drop cords to increase output and reduce operator variability.
The CLX-BPO2 auto-stripping machine 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 or steel strength members to precise stub lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and low downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors give exact positioning and closed-loop control. Inline checks update SPC charts so operators can adjust drifts before out-of-control conditions occur.
| Feature | Capability | Benefit |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Drive | Pneumatic cylinders | Fast/reliable motion |
| Materials | LSZH/PVC; FRP/steel | Clean, accurate preps |
| Process control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic feeders maintain clean workcells.
- Process control plans document calibration and key parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets without compromising accuracy.
CLX-BPO2 auto-stripping machine capabilities in our line
The CLX-BPO2 provides industrial-grade strip/trim to our line, cutting 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 helps keep strip lengths and reserved strength stubs within tight tolerances.
Throughput & Cycle Time
Typical operation speed is 1.5s per cycle. This translates to steady throughput under continuous line 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 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 adjacent fibers. Custom tooling are available for non-standard cross-sections to maintain precision.
- Automatic waste ejection and sensor-triggered start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass simplify cell integration.
- Cylinder-driven motion and PLC/photoelectric control improve line reliability and reduce maintenance downtime.
| Spec | Rating | Why it matters |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5–35.0 mm | Fits common connector processes |
| Stub (B) | 7.0 to 11.0 mm | Supports termination strength |
| Power & size | 110–220V, 50W; 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 compromising quality.
Custom Specs for Your FTTH System
Shanghai Weiye OFC Equipment configures every order to meet your network requirements and simplify field rollout. We combine focused options with predictable schedules so your teams get install-ready reels.
Choose 1–4 core designs with SM or MM fiber. Options include OS1/OS2 plus OM2–OM4 plus 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 print legends and logos support inventory and warranty tracking.
Put-Ups, Packaging, and Structures
Standard put-ups are 1 km, 2 km, and 4 km with tailored reels and packaging to fit storage/handling. Choose flat bow-type or self-supporting and steel wire or FRP strength members to fit span and isolation requirements.
| Choice | Common choice | Benefit |
|---|---|---|
| Reel length | 1, 2, or 4 km | Simpler staging and reels |
| Sheath | LSZH / PE / PVC | Indoor/Outdoor fit |
| Structure | Bow-type / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye schedules runs to your plan and delivers documentation that lists final specifications for straightforward QA on site.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment builds checkpoints into production so every item ships with recorded acceptance data.
Lab Testing: Heat, Salt Spray & Vibration
Our lab conducts elevated-temperature exposure, salt spray corrosion, and vibration tests 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 prevent nonconforming shipments before they leave the factory.
Audit Trail and Compliance
Batch records tie test data to reels and serials so audits and claims are easy to verify. Documentation follows common customer templates to accelerate approvals and receiving inspection.
- Line checks and final inspection reduce field failures and lower warranty events.
- QA packages include specifications confirmation and formatted test data for quick review.
- Ongoing trend analysis drive preventive maintenance and raise long-term reliability.
| Trial | Why | Result |
|---|---|---|
| Heat exposure | Material stability | Pass at target temperature |
| Salt-fog | Corrosion robustness | Qualified for outdoor use |
| Mechanical vibration | Mechanical robustness | Reduced field failures |
Pricing and cost drivers for FTTH drop cable
Budgeting for a drop run begins with fiber/jacket selection 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 chemistry (LSZH, PVC, PE), reel length, and structural design.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber grade, sheath material, and the structural type chosen for deployment.
Self-supporting structures and steel members increase material/labor. Custom sheath colors/logos/legends add setup and influence price for short runs.
Length/Volume/Customization Impact
Longer reels and higher volume orders lower unit cost. Short runs often include setup charges 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.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Factor | Effect on price | Guidance |
|---|---|---|
| Fiber grade | High impact | Balance spec vs. budget |
| Sheath material | Medium | Compare LSZH vs. PE for total cost |
| Order 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 crews and sites. Predictable windows reduce downtime and help control cost 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 plan capacity to track your milestones and to maintain on-time delivery.
The service team provides updates/tracking so installation teams can plan arrivals. For compressed schedules, we reserve contingency capacity to accelerate critical-path orders.
MOQ and Rationale
The MOQ is 1 km. This reflects setup needs such as wire/die adjustments that consume start-up material and scrap.
We review your put-ups and staging to select reels to reduce waste/handling. Batch releases can balance inventory holding with frequent, smaller deliveries to job sites.
Installation Scenarios & Readiness
Site conditions determine whether a self-supporting aerial, ducted pull, or direct-buried run is the right choice 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 sheaths and crush-resistant builds so pulling does not damage fibers. PE jackets are common for underground and buried paths where moisture resistance is needed.
Direct-buried designs require proper depth control per local codes and moisture-resistant jackets to protect the optic core over time.
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 stubs for quick ONT termination.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning exposure, and hardware compatibility. Standardized line prep shortens install time and reduces scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Underground duct | Low-friction jacket, crush resistance | Use pull tape + lubricant |
| Direct burial | PE with moisture barrier | Follow depth/warning tape codes |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at wall penetrations |
Our approach delivers a consistent installation across indoor/outdoor transitions. That leads to fewer callbacks, faster activations, and stable 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 capture through approved drawings and pilot builds. We deliver documentation templates and clear install notes so field crews work from the same plan.
After-sales service includes fast response, RCA, and corrective action. All products ship with full reports and traceability to support QA acceptance.
- 24/7 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.
| Support area | What we do | Benefit |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| QA/Testing | Lab trials & 100% test reports | Full traceability |
| After-sales | Rapid replacement & root-cause | Lower downtime |
Conclusion
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 trials to support U.S. field acceptance.
A hardened production line, including CLX-BPO2-enabled prep machines, reduces variability and speeds turnaround. Our equipment set standardize strip and stub lengths so installers see consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance design and cost to maximize service life. Dedicated support guides scheduling, logistics, and after-sales care 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 lab validation and responsive service.
