Fiber-to-the-Home Cable Production: Step-by-Step Manufacturing Process
Surprising fact: more than seventy percent of new U.S. broadband builds now depend on fiber networks that require tight manufacturing control to hit performance targets.
Shanghai Weiye OFC Equipment manages full-cycle fiber secondary coating line manufacturing, from sourcing brand fibers like Fujikura or Corning SMF-28e to comprehensive test documentation that deliver 100% QA.
Our FTTH drop designs suit overhead, ducted, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and polyethylene (PE) jacket options and arrangements from 1–4 cores. We provide single-mode OS1/OS2 and multimode OM2–OM4 grades plus G.652D and G.657 variants, Pantone sheath colors, and custom logo printing.
Automated machines and high-precision equipment keep line speed steady 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 MOQ of 1 km and warranty for free replacement on 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 offers end-to-end manufacturing and lab testing for United States projects.
- Multiple jacket choices and optical grades cover different install environments.
- Automated production lines provide stable quality and reliable optical performance.
- Fast lead times, low MOQ, 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 schedules and performance count, Shanghai Weiye OFC Equipment delivers tailored drop solutions with full test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment pairs specialized equipment with stringent material control. We offer customized service and products for single-family and MDU rollouts. Every order comes with 100% quality assurance and full test reports.
Our lab conducts high-temperature, salt-fog, and vibration testing to verify durability. Jacket options cover LSZH, PVC, and PE. Designs include bow-type flat and self-supporting styles and support brand fibers such as Fujikura and Corning SMF-28e.
- Documented line control and in-process checks for fully auditable shipments.
- Technical support for specs, trials, and ramp to volume.
- Modern fixturing and calibration minimize variation so every cable matches operator specs.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are built around network requirements, pairing brand fiber choices with disciplined test flows.
Selecting Optical Fiber and Brands
We select fiber ribbon line to minimum bend radius, loss, and install environment. 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 offered to meet procurement standards.
Strength Member Options
Strength members use FRP (dielectric) or metallic steel wire. FRP is preferred where non-conductivity is necessary. Steel wire provides tensile strength for long-span aerial runs and grounding needs.
Jacket extrusion and process control
Jacket options include LSZH for indoor flame safety, PVC for flexibility, and PE for outdoor UV and moisture resistance. Closed-loop control of temperature and capstan ratios keeps line speed stable and critical dimensions.
| Member | Dielectric FRP | Steel wire |
|---|---|---|
| Use case | Non-conductive runs | High-tension aerial runs |
| Key benefit | Lightweight, inert | High strength |
| Installer note | Easier terminations | Bonding/grounding required |
Inline and final testing
Inline geometry/concentricity checks operate in-line. Final optical tests verify attenuation and reflectance. 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 4–5 days for < 100 km and 7–10 days for < 500 km. Lot records and first-article approvals provide traceability and compliance for U.S. programs.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment offers a focused 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 flat bow-type drop minimizes footprint for risers and conduit. It reduces bend loss for simple routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs include a messenger element to handle tension. Choose FRP (dielectric) for electrical isolation or steel wire when bonding/grounding and higher tensile strength are required.
Strength member and core layouts
We offer both 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.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor UV and moisture resilience. Each family is qualified for mechanical/optical performance before shipment.
| Type | Application | 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 fiber counts | Dielectric FRP | LSZH/PE |
| Unitube flat | Low count, quick strip | FRP/Steel | LSZH/PE |
Equipment Ensuring Quality and Throughput
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 auto-stripping machine runs under PLC and photoelectric control. One cycle is about 1.5 seconds, giving real-world speeds near 20 terminal operations per minute.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH and PVC jackets and trims FRP or steel strength members to precise reserved lengths. Pneumatic cylinder actuators provide quick, repeatable motion and low downtime.
PLC & Photoelectric for Precision
PLC logic + photoelectric sensors give exact positioning and closed-loop control. Inline checks feed control charts so operators can adjust drifts before out-of-control conditions occur.
| Item | Spec | Benefit |
|---|---|---|
| CLX-BPO2 | 1.5s cycle, auto-strip | High throughput |
| Drive | Pneumatic cylinders | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Process control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Automated waste ejection and ergonomic feeders maintain clean workcells.
- Process control plans document calibration and key parameters.
- Integrated assets and trained operators help meet FTTH volume goals without compromising accuracy.
CLX-BPO2 auto-stripping machine capabilities in our line
The CLX-BPO2 provides industrial-grade strip/trim 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 cycles in ~1.5 seconds, producing around 20 preps per minute in production.
PLC and photoelectric control deliver exact detection and repeatable motion. 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 strips LSZH and PVC jackets with an adjustable jacket strip length from 17.5–35.0 mm. Reserved stubs are set between 7.0 and 11.0 mm to fit common termination hardware.
Handling FRP and steel wire strength members
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Customized cutters are available for nonstandard sizes to maintain precision.
- Automatic waste ejection and sensor start cut idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass ease integration into workcells.
- Pneumatic cylinders and closed-loop control boost reliability and reduce maintenance downtime.
| Spec | Rating | Why it matters |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Reserved 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 get drop parts install-ready. The CLX-BPO2 supports our lines in meeting volume targets without sacrificing quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures every order to meet 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 SM or MM fiber. Options include OS1/OS2 plus OM2–OM4 plus 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.
Jacket materials, print legends, and branding
Select LSZH/PVC/PE jackets based on route and safety rules. Custom legends/logos aid inventory/warranty tracking.
Length options, packaging, and special structures
Standard put-ups are 1/2/4 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 meet span and isolation needs.
| Option | Common choice | Advantage |
|---|---|---|
| Length | 1 / 2 / 4 km | Simpler staging and reels |
| Sheath | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Structure | Flat bow / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye schedules runs to your plan and delivers documentation that lists final specifications for easy on-site QA.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item has recorded acceptance data at ship.
Lab Testing: Heat, Salt Spray & Vibration
Our lab conducts high-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials/assemblies. These tests simulate field stresses for indoor/outdoor applications.
100% test reports for every cable
Every fiber optic cable ships with a 100% test report that records loss, return loss, and key geometry where applicable. Final inspection gates prevent nonconforming shipments before they leave the factory.
Audit Trail and Compliance
Batch records link tests to reels/serials so audits and warranty claims are simple to verify. Documentation uses standard customer templates to accelerate approvals and receiving inspection.
- In-line checks plus final inspection reduce field failures and lower warranty events.
- QA packages include spec confirmation and formatted data for rapid review.
- Continuous test trends drive preventive maintenance and improve long-term reliability.
| Test | Why | Outcome |
|---|---|---|
| Heat exposure | Thermal stability | Validated heat endurance |
| Salt-fog | Corrosion resistance | Qualified for outdoor use |
| Vibration | Mechanical robustness | Reduced field failures |
FTTH Drop Cable Pricing & Cost Drivers
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, length, and design structure.
Primary Cost Inputs
The primary cost drivers are fiber grade, jacket material, and the structural type chosen for deployment.
Self-supporting designs and steel members raise material and labor input. Custom colors, logos, and print legends add setup and impact pricing on small runs.
Length/Volume/Customization Impact
Longer reels and higher volume orders lower unit cost. Small quantities often include setup charges and higher unit prices.
- Changeovers and special cutters increase lead time and add cost.
- Clear RFQs with schedule alignment let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets over phases.
| Factor | Price impact | Recommendation |
|---|---|---|
| Fiber grade | High impact | Right-size spec to budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Length/Volume | Large | Consolidate where possible |
U.S. Lead Times, MOQ & Delivery
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.
Typical production windows and capacity planning
Typical production windows are 4–5 days for < 100 km and 7–10 days for orders under 500 km. We plan capacity to track your milestones and to maintain on-time delivery.
The service team issues production updates and tracking so installation teams know when reels arrive. For tight schedules, we hold 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. Staggered batches can balance inventory holding with more frequent small-site deliveries.
Where and How to Deploy
Site conditions dictate whether a self-supporting aerial, ducted pull, or direct burial is the best fit for a project.
Aerial vs Duct vs Direct-Buried
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with appropriate 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 typical for underground and buried paths where moisture resistance is needed.
Direct-buried designs need correct burial depth per local codes and moisture barriers to protect the optic core over time.
Indoor Distribution and ONT
Indoor riser and plenum routes favor LSZH jackets to meet flame and smoke rules. Flat drop cable forms strip clean and present controlled strength stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding requirements, lightning risk, and hardware fit. Standardized line prep shortens install time and reduces scrap.
| Deployment | Key design | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Duct | Low-friction, crush-resistant | Use pull tape and proper lubricant |
| Direct burial | 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 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 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 test reports and traceability to help QA acceptance.
- 24/7 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 requirements every time.
| Area | Scope | Outcome |
|---|---|---|
| Engineering | Spec review & pre-production builds | Fewer field issues |
| QA/Testing | Lab + 100% reports | Full traceability |
| After-sales | Fast replace + RCA | Lower downtime |
Wrap-Up
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
We deliver customized FTTH drop solutions that pair material choices with validated manufacturing and lab testing. Every reel ships with a 100% test report and documented trials to support field acceptance in the United States.
A hardened production line, including CLX-BPO2 prep assets, cuts variability and speeds turnaround. Our equipment set standardize strip and 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 remains on plan.
Contact Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every shipment with laboratory validation and responsive support.