Fiber-to-the-Home Cable Production: Step-by-Step Manufacturing Process
Did you know: in excess of 70% of U.S. broadband rollouts now use fiber networks that require precise manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment runs full-cycle compact fiber unit manufacturing, from selecting brand fibers like Fujikura or Corning® SMF-28e to complete test reports that guarantee full quality assurance.
Our drop cable designs fit overhead, ducted, and direct-buried installation, with low-smoke zero-halogen (LSZH), PVC, and PE jacket options and configurations from 1 to 4 cores. We offer OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automation and precision equipment stabilize line speed and maximize repeatability. Typical lead times run 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.
Keep reading to see how materials, testing, and support work together to reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment delivers end-to-end manufacturing and lab testing for United States projects.
- Multiple jacket choices and optical grades support different install environments.
- Automated production lines ensure stable quality and reliable optical performance.
- Fast lead times, low MOQ, and recognized brand fibers keep procurement predictable.
- Comprehensive test reports and after-sales warranty support product reliability and documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment delivers tailored drop solutions with full test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment combines purpose-built equipment with tight material control. We provide customized service and products for single-family and MDU rollouts. Every order includes 100% quality assurance and complete test reports.
Our lab conducts high-temperature, salt-fog, and vibration testing to validate durability. Jacket options cover LSZH, PVC, and PE. Designs cover bow-type flat and self-supporting styles and support brand fibers such as Fujikura and Corning SMF-28e.
- Controlled production lines and production checks for shipments with audit trails.
- Engineering support for specification reviews, trials, and volume ramp.
- Modern fixtures and calibration reduce variability so every cable meets operator standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, combining brand fiber choices with strict test routines.
Optical fiber selection and brand options
We select FTTH cable production line to minimum bend radius, loss, and deployment type. 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 available to meet procurement standards.
Strength Member Options
Strength members use dielectric FRP or galvanized steel wire. FRP is ideal where non-conductive runs are required. Steel wire provides tensile strength for long-span aerial runs and 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 extruder temperature and capstan speed keeps line speed stable and dimensional tolerances.
| Member | Dielectric FRP | Metallic Steel |
|---|---|---|
| Primary use | Non-conductive runs | Aerial spans, high tensile |
| Key benefit | Light, non-corrosive | Very high tensile strength |
| Installation note | Simple terminations | Requires grounding |
In-Process and Final Testing
Inline geometry/concentricity checks operate in-line. Final optical tests confirm attenuation and reflectance. Each order includes a full test report and lab results from high-temperature, salt fog, and vibration tests 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 FAI approvals support traceability and compliance for U.S. projects.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment provides a compact portfolio of FTTH 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 and conduit. It keeps bend loss low for easy routing in MDU corridors and hallways.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs include a support messenger to carry tensile loads. Choose dielectric FRP for electrical isolation or steel wire when bonding/grounding and extra tensile strength are required.
Layouts & Strength Members
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 compact fiber unit 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 series is validated for mechanical and optical quality before shipment.
| Design | Best use | Strength member | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting (aerial) | Overhead spans | Steel wire or FRP | Polyethylene |
| Center loose tube | Higher-count builds | FRP | LSZH/PE |
| Unitube flat | Low count, quick strip | FRP or steel | LSZH or PE |
Production Assets for Speed and Quality
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and increase throughput for drop patch preparation.
Our production line uses automated machines that cut and strip drop patch cords to raise throughput and cut labor variability.
The CLX-BPO2 auto-stripping machine uses PLC + photoelectric control. One cycle is about 1.5 seconds, giving ~20 terminals per minute in production.
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.
Closed-Loop Control for Repeatability
PLC logic and photoelectric sensors deliver precise positioning and closed-loop control. Inline checks feed control charts so operators can adjust drifts before defects grow.
| Feature | Capability | Benefit |
|---|---|---|
| CLX-BPO2 | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Actuation | Pneumatic cylinders | Fast/reliable motion |
| Material handling | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Automated waste ejection and ergonomic loading keep the line clean.
- Process control plans capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without sacrificing accuracy.
CLX-BPO2 Capabilities on 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 converts 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 stubs are adjustable from 7.0–11.0 mm to match common termination hardware.
FRP & Steel Member Handling
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Custom tooling are available for non-standard cross-sections to preserve precision.
- Automatic waste ejection and sensor start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass ease integration into workcells.
- Cylinder-driven motion and PLC/photoelectric control improve line reliability and lower maintenance interruptions.
| Specification | Rating | Benefit |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Fits common connector processes |
| Stub (B) | 7.0–11.0 mm | Meets strength and termination needs |
| Power/Size | 50W @ 110–220V; 40×18×18 cm | Easy integration into existing equipment |
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 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 combine focused options with predictable schedules so your teams get install-ready reels.
Choose 1 to 4 cores with single-mode or multimode fiber. Options include OS1, OS2, and OM2–OM4 plus G.652D/G.657 variants to align with 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, or PE jackets based on route and safety rules. Custom print legends and logos aid inventory/warranty tracking.
Lengths, Packaging & Special Builds
Standard reel lengths are 1 km, 2 km, and 4 km with custom 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.
| Option | Typical | Advantage |
|---|---|---|
| Length | 1 / 2 / 4 km | Simpler staging and reels |
| Sheath | LSZH / PE / PVC | Indoor/Outdoor fit |
| Design | Flat bow / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye schedules runs to your plan and provides docs that detail final specs for straightforward QA on site.
QA, Testing & 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 vibration tests to qualify materials/assemblies. These tests recreate field stresses for indoor/outdoor applications.
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 stop nonconforming items before they leave the factory.
Traceability and compliance
Lot/batch records link tests to reels/serials so audits and claims are easy to verify. Documentation follows common customer templates to accelerate approvals and receiving inspection.
- In-line checks plus final inspection prevent field failures and cut warranty events.
- Quality packages include spec confirmation and formatted test data for quick review.
- Ongoing trend analysis inform preventive maintenance and raise long-term reliability.
| Trial | Why | Outcome |
|---|---|---|
| Heat exposure | Thermal stability | Pass at target temperature |
| Salt spray | Corrosion resistance | Outdoor suitability |
| Vibration | Resistance to vibration | Reduced field failures |
Cost Drivers and Pricing
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 to $1,000 per unit—based on fiber grade, jacket chemistry (LSZH, PVC, PE), reel length, and design structure.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber optic grade, sheath material, and the structural type chosen for deployment.
Self-supporting designs and steel members increase material/labor. Custom sheath colors/logos/legends add setup and influence price for short runs.
Order length, volume, and customization impact on price
Longer reels and higher volume orders reduce unit cost. Small quantities 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 align price quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets over phases.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Fiber grade | High impact | Right-size spec to budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Order length / volume | Large | Consolidate runs to cut unit cost |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews and sites. Predictable schedules cut downtime and help control cost when a rollout is underway.
Production Windows & Capacity
Typical production windows are 4–5 days for < 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 can plan arrivals. For compressed schedules, we hold contingency capacity to accelerate critical-path orders.
Why MOQ Matters
The MOQ is 1 km. This reflects line setup such as wire and jacket 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 holding with frequent, smaller deliveries to job sites.
Installation Scenarios & Readiness
Site conditions determine whether a self-supporting span, duct pull, or direct burial is the right choice 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 manage sag/tension for long-term reliability.
Duct installations work 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 matters.
Direct-buried designs need correct burial depth per local codes and moisture barriers to protect the optic core over time.
Indoor Riser/Plenum & ONT
Indoor riser/plenum routes favor LSZH jackets to meet flame and smoke rules. Flat drop cable forms strip clean and present controlled stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware compatibility. Standardized line prep shortens install time and reduces scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Underground duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow depth/warning tape codes |
| Interior | LSZH with tight-bend support | Maintain bend radius at penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That leads to fewer callbacks, speeds activations, and stable field performance for your system.
Support from Spec to Service
Our team coordinates tests, line schedules, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements through approved drawings and pilot builds. We provide doc 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 reports and traceability to help QA acceptance.
- Round-the-clock availability for status and technical support.
- Warranty with free replacement if any quality problems are confirmed.
- Schedule coordination for urgent changes or acceleration requests.
- Config control so shipped items match agreed specs consistently.
| Area | Scope | Outcome |
|---|---|---|
| Tech/Eng | Specs + pilots | Fewer field issues |
| QA/Testing | Lab + 100% reports | Traceable quality |
| Service | Fast replace + RCA | Lower downtime |
Final Thoughts
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
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 trials to support U.S. field acceptance.
A hardened 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 to jacket, printing, and packaging, we balance performance and cost to extend service life. Dedicated support covers scheduling/logistics/after-sales so your deployment stays 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 laboratory validation and responsive service.