Fiber-to-the-Home Cable Production: Manufacturing Process Explained
Quick fact: more than seventy percent of new broadband deployments in the U.S. now depend on fiber networks that require precise manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment manages complete compact fiber unit manufacturing, from sourcing brand fibers like Fujikura® or Corning® SMF-28e to complete test reports that deliver 100% QA.
Our drop designs fit aerial, ducted, and direct burial installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and PE jacket options and configurations from 1 to 4 cores. We supply OS1/OS2 and multimode OM2–OM4 grades plus G.652D and G.657 variants, Pantone sheath colors, and logo printing.
Automation and high-precision equipment stabilize line speed and keep repeatability high. Typical lead times are four to five days for orders under 100 km and seven to ten days under 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 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 United States projects.
- A range of jacket options and fiber grades support varied installation environments.
- Automated production lines ensure stable quality and stable optical performance.
- Quick lead times, low MOQ, and brand fiber options support reliable procurement planning.
- Complete reports and after-sales warranty support product reliability and documentation needs.
FTTH Manufacturing Expertise 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 combines specialized equipment with tight material control. We provide customized service and products for single-family and MDU rollouts. Every order comes with full QA coverage and complete test reports.
Our lab conducts high-temperature, salt-fog, and vibration tests to verify durability. Jacket options include LSZH, PVC, and PE. Designs include 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 auditable shipments.
- Technical support for specification reviews, trials, and volume ramp.
- Modern fixtures and calibration minimize variation so every cable matches operator specs.
How We Produce FTTH Cable
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 minimum bend radius, loss, and deployment type. Options include OS1/OS2 and OM2–OM4 and ITU-T G.652D, G.657.A1/A2. Brand fibers such as Fujikura and Corning SMF-28e are available to meet procurement standards.
Strength Member Options
Strength members employ dielectric FRP or galvanized steel wire. FRP is preferred where non-conductive runs are required. Steel wire provides tensile strength for longer aerial spans and bonding/grounding needs.
Extrusion & Process Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility, 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 | Dielectric FRP | Steel wire |
|---|---|---|
| Use case | Electrical isolation | High-tension aerial runs |
| Key benefit | Lightweight, inert | Very high tensile strength |
| Installation note | Easier terminations | Bonding/grounding required |
Testing & Verification
Inline geometry and concentricity checks operate in-line. Final optical tests confirm attenuation and return loss. Each order ships with a 100% test report and lab results from high heat, salt-spray, and vibration trials to qualify field handling and drop terminations.
Typical lead times are under 100 km in 4–5 days and 7–10 days for < 500 km. Material lot records and first-article approvals support traceability and compliance for U.S. programs.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment offers a compact portfolio of drop designs that suit both 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 minimizes footprint for risers/ducts. It reduces bend loss for simple routing in MDU corridors and hallways.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs use a support messenger to handle tension. Choose FRP (dielectric) for electrical isolation or steel messenger when bonding and extra tensile strength are required.
Core Layouts and Strength Members
We offer both dielectric and metallic strength member configurations to match safety and EMI rules. Central loose-tube and unitube flat types balance crush resistance and fiber secondary coating line for quick termination.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor UV and moisture resilience. Each series is validated for mechanical and optical quality before shipment.
| Design | Best use | Strength element | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | Dielectric FRP | LSZH |
| Self-supporting (aerial) | Aerial spans | Steel wire or FRP | PE |
| Central loose-tube | Higher-count builds | Dielectric FRP | LSZH or PE |
| Flat unitube | Low-count, easy strip | FRP or steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for drop patch preparation.
Our production line uses automated machines that cut/strip drop cords to raise throughput and cut labor variability.
The CLX-BPO2 auto-stripping machine uses PLC + 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 or steel strength members to precise stub lengths. Pneumatic cylinder actuators provide quick, repeatable motion and minimize 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 defects grow.
| Feature | Capability | Result |
|---|---|---|
| CLX-BPO2 | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Material handling | LSZH/PVC; FRP/steel | Clean, accurate preps |
| Control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic feeders maintain clean workcells.
- PCPs document calibration and key parameters.
- Integrated assets and trained operators help meet FTTH volume goals without sacrificing 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 uses the CLX-BPO2 to raise output and standardize terminal 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 enable precise detection and repeatable motion. That control keeps strip and stub lengths within tight tolerances.
Cycle time and throughput
Typical operation speed is 1.5s per cycle. This converts to steady throughput under normal production conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable strip length from 17.5–35.0 mm. Reserved 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 adjacent fibers. Customized cutters are offered for nonstandard sizes to preserve precision.
- Auto-eject scrap and sensor start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight simplify cell integration.
- Pneumatic cylinders and PLC/photoelectric control improve line reliability and reduce maintenance downtime.
| Spec | Rating | Benefit |
|---|---|---|
| Cycle time | ~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 to 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 prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 helps our production lines meet volume goals without compromising quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures each build to fit your network requirements and simplify field rollout. 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 along with G.652D and G.657 variants to align with optics and connector plans.
We match sheath colors to Pantone codes for quick field identification and consistent asset tags.
Jackets, Legends & Branding
Select LSZH/PVC/PE jackets based on route and safety rules. Custom legends/logos support inventory and warranty tracking.
Length options, packaging, and special structures
Standard put-ups are 1/2/4 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 meet span and isolation needs.
| Option | Common choice | Benefit |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and reels |
| Sheath | LSZH / PE / PVC | Indoor/Outdoor fit |
| Structure | Flat bow / Self-supporting | Routing and span flexibility |
As a supplier, Shanghai Weiye aligns runs to your schedule and delivers documentation that detail final specs for straightforward QA on site.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item ships with recorded acceptance data.
Lab Testing: Heat, Salt Spray & Vibration
Our lab runs elevated-temperature exposure, salt spray corrosion, and vibration tests to qualify materials and 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 records loss, return loss, and key geometry where applicable. Final QC gates prevent nonconforming shipments before they leave the factory.
Traceability & Compliance
Batch records link tests to reels/serials so audits and claims are easy to verify. Documentation uses standard customer templates to accelerate approvals and receiving inspection.
- In-line checks plus final inspection reduce field failures and cut warranty events.
- QA packages include specifications confirmation and formatted test data for rapid review.
- Continuous test trends drive preventive maintenance and improve long-term reliability.
| Trial | Purpose | Outcome |
|---|---|---|
| Heat exposure | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion robustness | Outdoor suitability |
| Vibration | Resistance to vibration | Reduced field failures |
FTTH Drop Cable Pricing & Cost Drivers
Budgeting for a drop run starts with fiber and jacket choices and is shaped by volume and customization.
Typical prices vary widely—from about $30–$1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket material, length, and structural design.
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 increase material/labor. Custom sheath colors/logos/legends add setup time and influence price for short runs.
Order length, volume, and customization impact on price
Longer reels and higher volume orders lower unit cost. Small quantities often carry setup fees and higher per-unit charges.
- Changeovers and special cutters extend lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets across phases.
| Driver | Price impact | Guidance |
|---|---|---|
| Optical grade | Large | Balance spec vs. budget |
| Sheath material | Medium impact | Evaluate LSZH vs PE |
| Order 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 cut downtime and control costs when a rollout is underway.
Typical production windows and capacity planning
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 keep deliveries on time.
The service team provides updates/tracking so installation teams know when reels arrive. For tight schedules, we hold contingency capacity to pull in 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 choose reel sizes that cut waste and handling. Batch releases can balance inventory with more frequent small-site deliveries.
Installation readiness and application scenarios
On-site conditions dictate whether a self-supporting span, duct pull, or direct burial 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 stability.
Duct installations perform best with low-friction jackets and crush-resistant builds so pulling avoids fiber damage. 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 fiber core long-term.
Indoor Riser/Plenum & ONT
Indoor riser/plenum routes favor LSZH jackets to meet smoke/flame codes. 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 needs, lightning exposure, and hardware compatibility. Standardized prep from the production line reduces install time and reduces scrap.
| Deployment | Key feature | Installer note |
|---|---|---|
| Aerial | 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 depth/warning tape codes |
| Indoor | LSZH with tight-bend support | Maintain bend radius at penetrations |
Our approach delivers a consistent installation across indoor/outdoor transitions. That leads to fewer callbacks, speeds activations, and stable field performance for your system.
End-to-end support and after-sales service
Our team coordinates testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment offers 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 reports and traceability to support QA acceptance.
- 24/7 availability for status updates and technical guidance.
- Warranty includes free replacement for confirmed quality issues.
- Schedule coordination for expedites and urgent changes.
- Config control so shipped items match agreed requirements every time.
| Support area | Scope | Benefit |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Fewer field issues |
| Testing | Lab + 100% reports | Full traceability |
| Service | Rapid replacement & root-cause | Lower downtime |
Final Thoughts
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
We deliver customized FTTH drop solutions 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 robust production line, including CLX-BPO2-enabled prep machines, cuts variability and speeds turnaround. Our equipment and machines standardize strip/stub lengths so installers see consistent results at turn-up.
From fiber selection through 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 remains on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every fiber optic and optic cable shipment with lab validation and responsive service.