Fiber-to-the-Home Cable Production: Step-by-Step Manufacturing Process
Did you know: over 70% of new U.S. broadband builds now depend on fiber networks that require high-precision manufacturing 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 complete test reports that guarantee full quality assurance.
Our FTTH drop designs fit aerial, ducted, and direct-buried installation, with low-smoke zero-halogen (LSZH), PVC, and PE jacket options and arrangements from 1 to 4 cores. We supply single-mode OS1/OS2 and multimode OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone-matched sheath colors, and logo printing.
Automated machines and precision equipment stabilize line speed and keep repeatability high. Typical lead times are 4–5 days for orders under 100 km and seven to ten days under 500 km, with an MOQ of 1 km and free-replacement warranty for quality problems.
Keep reading to see how materials, testing, and support work together to reduce lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment delivers complete production and laboratory testing for United States projects.
- Multiple jacket choices and fiber grades cover different install environments.
- Automated production lines provide stable quality and reliable optical performance.
- Quick lead times, low MOQ, and brand fiber options help plan procurement reliably.
- Comprehensive test reports and after-sales warranty back product reliability and compliance 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 pairs specialized 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-fog, and vibration testing to validate durability. Jacket options cover LSZH, PVC, and PE. Designs include bow-type flat and figure-8/self-supporting styles and use brand fibers such as Fujikura and Corning SMF-28e.
- Documented line control and production checks for auditable shipments.
- Technical support for specification reviews, trials, and volume ramp.
- Modern fixtures and calibration minimize variation 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.
Optical fiber selection and brand options
We align fiber secondary coating line to bend radius, loss, 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.
Strength Member Options
Strength members use dielectric FRP or metallic steel wire. FRP is ideal where non-conductive runs are required. 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.
| Component | FRP | Steel wire |
|---|---|---|
| Use case | Non-conductive runs | Aerial spans, high tensile |
| Advantage | Light, non-corrosive | High strength |
| Installation note | Simple terminations | Bonding/grounding required |
Testing & Verification
Inline geometry/concentricity checks operate in-line. Final optical tests verify attenuation and return loss. Each order ships with a full test report and lab results from high-temperature, salt fog, and vibration trials to confirm handling for drop terminations and field use.
Typical lead times are under 100 km in 4–5 days and under 500 km in 7–10 days. Material lot records and first-article approvals provide traceability and compliance for U.S. programs.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment offers a focused portfolio of FTTH drop designs that fit indoor risers and long aerial runs. 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 keeps bend loss low for simple routing in MDU corridors and hallways.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs include a support messenger to handle tension. Choose dielectric FRP for non-conductive runs or steel messenger when bonding and higher tensile strength are required.
Core Layouts and Strength Members
We offer dielectric and metallic strength member configurations to match safety and EMI rules. Center loose tube and flat unitube types balance crush resistance and compact fiber unit for fast terminations.
Indoor/outdoor jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor UV and moisture resilience. Each series is qualified for mechanical and optical quality before shipment.
| Type | Best use | Strength member | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting (aerial) | Aerial spans | FRP/Steel | Polyethylene |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH or PE |
| Flat unitube | Low count, quick strip | FRP/Steel | LSZH or PE |
Production Assets for Speed and Quality
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment cut 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 cut labor variability.
The CLX-BPO2 automated stripper runs under PLC and photoelectric control. One cycle is ~1.5 s, giving ~20 terminals per minute in production.
Automated Cut/Strip for Drop Cords
The equipment strips LSZH and PVC jackets and trims FRP or steel strength members to precise stub lengths. Cylinder-driven actuators deliver fast, repeatable motion and minimize downtime.
Closed-Loop Control for Repeatability
PLC logic + photoelectric sensors deliver precise positioning and closed-loop control. Inline checks update SPC charts so operators can adjust drifts before out-of-control conditions occur.
| Item | Spec | Benefit |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic feeders maintain clean workcells.
- PCPs capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff 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 keeping prep consistent.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to increase throughput and standardize prep quality. The unit cycles in ~1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC and photoelectric control deliver exact detection and repeatable motion. That control keeps strip and stub lengths within tight tolerances.
Line Speed
Typical operation speed is 1.5s per cycle. This enables steady throughput under continuous line conditions.
Supported jacket and reserved strength lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable jacket strip length from 17.5 to 35.0 mm. Reserved stubs are adjustable from 7.0–11.0 mm to match common termination hardware.
Handling FRP and steel wire strength members
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Custom tooling 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 PLC/photoelectric control boost reliability and lower maintenance interruptions.
| Specification | Rating | Benefit |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5–35.0 mm | Compatible with common connectors |
| Reserved stub (B) | 7.0–11.0 mm | Meets strength and termination needs |
| Power & size | 110–220V, 50W; 40×18×18 cm | Easy integration into existing equipment |
Using this machine, Shanghai Weiye OFC Equipment standardizes prep so field teams get drop parts install-ready. The CLX-BPO2 helps our production lines meet volume goals without compromising quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures each build to fit your network requirements and simplify deployment. We pair concise options with predictable manufacturing windows so your teams get install-ready reels.
Choose 1–4 core designs with SM or MM 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 tags.
Branding and Print Options
Select LSZH/PVC/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 1/2/4 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.
| Choice | Common choice | Benefit |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and reels |
| Jacket | LSZH, PE, PVC | Indoor/Outdoor fit |
| Structure | Bow-type / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye aligns runs to your schedule 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.
Lab Testing: Heat, Salt Spray & Vibration
Our lab conducts elevated-temperature exposure, salt fog corrosion, and vibration tests to qualify materials and assemblies. These tests recreate field stresses for indoor/outdoor applications.
100% test reports for every cable
Every fiber optic cable ships with a 100% test report that logs attenuation, return loss, and geometry where applicable. Final QC gates prevent nonconforming shipments before they leave the factory.
Audit Trail and Compliance
Lot/batch records tie test data to reels and serials so audits and claims are easy to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection prevent field failures and cut warranty events.
- QA packages include specifications confirmation and formatted test data for quick review.
- Ongoing trend analysis inform preventive maintenance and raise long-term reliability.
| Test | Why | Result |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt spray | Corrosion robustness | Outdoor suitability |
| Mechanical vibration | Resistance to vibration | Improved field reliability |
FTTH Drop Cable Pricing & Cost Drivers
Budgeting for a drop run begins with fiber/jacket selection and is refined by volume and customization.
Typical prices range broadly—from about $30–$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 chosen structure for deployment.
Self-supporting designs and steel strength elements raise material and labor input. Custom sheath colors/logos/legends add setup and influence price for short runs.
Order length, volume, and customization impact on price
Longer put-ups and larger volumes reduce unit cost. Small quantities often include setup charges and higher unit prices.
- Line changeovers and custom tooling increase lead time and add cost.
- Clear RFQs with schedule alignment let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Fiber grade | Large | Right-size spec to budget |
| Jacket type | Medium impact | Compare LSZH vs. PE for total cost |
| Order length / volume | High impact | Consolidate where possible |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align staffing and sites. Predictable schedules 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 orders under 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 know when reels arrive. For compressed schedules, we reserve contingency capacity to pull in critical-path orders.
MOQ and Rationale
The MOQ is one kilometer. This reflects line setup 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 with more frequent small-site deliveries.
Installation Scenarios & Readiness
On-site conditions determine whether a self-supporting span, ducted pull, or direct-buried run is the best fit for a project.
Deployment Considerations
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 work best with low-friction sheaths and crush-resistant constructs so pulling does not damage fibers. PE jackets are typical 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 Distribution and ONT
Indoor riser/plenum routes prefer LSZH to meet smoke/flame codes. Flat drop profiles strip clean and present controlled strength stubs for fast ONT terminations.
We guide the choice of steel or FRP (dielectric) strength members based on bonding requirements, lightning exposure, and hardware compatibility. Standardized line prep shortens install time and reduces scrap.
| Deployment | Key feature | Installer note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Duct | Low-friction jacket, crush resistance | Use pull tape + lubricant |
| Direct-buried | 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, speeds activations, and reliable field performance for your system.
Support from Spec to Service
Our team coordinates tests, line schedules, and installation guidance to remove surprises during 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 covers rapid response, root-cause analysis, and corrective actions. All products ship with full test reports and traceability to help QA acceptance.
- Round-the-clock availability for status updates and technical guidance.
- Warranty includes free replacement for confirmed quality issues.
- Schedule coordination for expedites and urgent changes.
- Configuration control so shipped items match agreed requirements every time.
| Support area | What we do | Outcome |
|---|---|---|
| Engineering | Spec review & pre-production builds | Fewer field issues |
| QA/Testing | Lab trials & 100% test reports | Traceable quality |
| After-sales | Rapid replacement & root-cause | Minimized downtime |
Final Thoughts
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 shortens turnaround. Our equipment set 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 support.
