Fiber-to-the-Home Cable Production: How the Manufacturing Process Works
Surprising fact: in excess of seventy percent of new broadband deployments in the U.S. now depend on fiber networks that demand tight manufacturing control to meet performance goals.
Shanghai Weiye OFC Equipment manages end-to-end Fiber cable sheathing line manufacturing, from selecting brand fibers like Fujikura or Corning® SMF-28e to complete test reports that guarantee full quality assurance.
Our drop designs fit overhead, underground, and direct burial installation, with low-smoke zero-halogen (LSZH), PVC, and PE jacket options and core counts from 1 to 4 cores. We offer single-mode OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automated machines and high-precision equipment keep line speed steady and maximize repeatability. Typical lead times run 4–5 days for orders under 100 km and seven to ten days for < 500 km, with an min. order of 1 km and warranty covering free replacement for confirmed quality issues.
Continue to understand how our materials, tests, 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 United States projects.
- Multiple jacket choices and fiber grades support different install environments.
- Automated production lines deliver consistent quality and stable 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.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment delivers customized drop cables with complete test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment combines specialized equipment with stringent material control. We offer customized service and products for residential/MDU deployments. Every order includes 100% quality assurance 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 offer flat bow-type and self-supporting styles and support brand fibers such as Fujikura and Corning SMF-28e.
- Documented line control and in-process checks for shipments with audit trails.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixtures and calibration minimize variation so every cable meets operator standards.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with disciplined test flows.
Fiber Selection & Brand Options
We align fiber draw tower to minimum bend radius, loss, and install environment. 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.
Integrating Strength Members
Strength members employ dielectric FRP or metallic 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 flame/smoke safety, PVC for flexibility, and PE for outdoor UV and moisture resistance. Closed-loop control of temperature and capstan ratios stabilizes line speed and dimensional tolerances.
| Member | Dielectric FRP | Metallic Steel |
|---|---|---|
| Use case | Non-conductive runs | High-tension aerial runs |
| Advantage | Light, non-corrosive | High strength |
| Installer note | Easier terminations | Requires grounding |
Testing & Verification
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 heat, 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. projects.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment provides 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 consistent optical performance.
The flat bow-type drop minimizes footprint for risers and conduit. It keeps bend loss low for easy routing in hallways and MDUs.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs include a support messenger to carry tensile loads. Choose dielectric FRP for electrical isolation or steel messenger when bonding/grounding and higher tensile strength are required.
Strength member and core layouts
We provide 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 series is qualified for mechanical/optical performance before shipment.
| Design | Application | Strength element | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting | Overhead spans | FRP/Steel | Polyethylene |
| Center loose tube | Higher-count builds | Dielectric FRP | LSZH/PE |
| Flat unitube | Low count, quick strip | FRP/Steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
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/strip drop cords to raise throughput and cut labor variability.
The CLX-BPO2 automated stripper 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 deliver precise positioning and feedback control. Inline checks update SPC charts so operators can adjust drifts before defects grow.
| Item | Capability | Benefit |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Material handling | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Process control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic loading 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 Capabilities on Our Line
The CLX-BPO2 provides industrial-grade strip/trim to our line, reducing cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment deploys the CLX-BPO2 to increase throughput and standardize terminal 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 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.
Jacket Strip & Stub 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.
Handling FRP and steel wire strength members
The machine cleanly cuts FRP and steel wire strength elements while protecting neighboring fibers. Customized cutters are offered for nonstandard sizes to maintain precision.
- Automatic waste ejection and sensor-triggered start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass simplify cell integration.
- Pneumatic cylinders and closed-loop control improve line reliability and lower maintenance interruptions.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | Supports high-volume runs |
| Strip lengths (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Reserved stub (B) | 7.0–11.0 mm | Supports termination strength |
| Power/Size | 50W @ 110–220V; 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 sacrificing quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures each build to meet 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 single-mode or multimode fiber. Options include OS1/OS2 plus OM2–OM4 plus G.652D/G.657 variants to match your optics and connector plans.
We Pantone-match sheath colors for quick field identification and consistent asset tagging.
Jacket materials, print legends, and branding
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom print legends and logos aid inventory/warranty tracking.
Length options, packaging, and special structures
Standard reel lengths are 1 km, 2 km, and 4 km with tailored reels and packaging to suit storage and handling. Choose bow-type flat or self-supporting designs and FRP or steel members to meet span and isolation needs.
| Choice | Typical | Advantage |
|---|---|---|
| Length | 1 / 2 / 4 km | Simpler staging and reels |
| Sheath | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Design | Flat bow / Self-supporting | Flexible routing/span |
As a supplier, 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 runs elevated-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials/assemblies. These tests recreate field stresses for indoor and outdoor use.
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 QC gates prevent nonconforming shipments before they leave the factory.
Traceability & Compliance
Lot/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 prevent field failures and lower warranty events.
- Quality packages include spec confirmation and formatted data for quick review.
- Continuous test trends inform preventive maintenance and improve long-term reliability.
| Trial | Why | Result |
|---|---|---|
| High-temperature | Material stability | Validated heat endurance |
| Salt spray | Corrosion robustness | Qualified for outdoor use |
| Vibration | Resistance to vibration | Reduced field failures |
Cost Drivers and Pricing
Budget planning for a drop 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, length, and design structure.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber grade, jacket material, and the chosen structure for deployment.
Self-supporting designs and steel strength elements increase material/labor. Custom sheath colors/logos/legends add setup time and impact pricing on small runs.
Length/Volume/Customization Impact
Longer put-ups and larger volumes reduce unit cost. Short runs often carry setup fees and higher per-unit charges.
- Line changeovers and custom tooling extend 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 across phases.
| Driver | Price impact | Guidance |
|---|---|---|
| Fiber grade | Large | Balance spec vs. budget |
| Sheath material | Medium impact | Evaluate LSZH vs PE |
| 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 windows reduce downtime and control costs 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 orders under 500 km. We schedule line capacity to track your milestones and to maintain on-time delivery.
The service team issues production updates and tracking so installation teams can plan arrivals. For compressed schedules, we hold contingency capacity to pull in critical-path orders.
Why MOQ Matters
The MOQ is 1 km. This reflects line setup such as wire and jacket die adjustments that use startup material and generate scrap.
We review your length and staging plans 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 determine whether a self-supporting aerial, ducted pull, or direct-buried run is the best fit 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 control sag and tension for long-term stability.
Duct installations perform best with low-friction sheaths 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 require proper depth control 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 cleanly and present controlled strength stubs for quick ONT termination.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning exposure, and hardware fit. Standardized line prep reduces install time and minimizes scrap.
| Deployment | Key feature | Field note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow local depth and warning tape rules |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at penetrations |
Our approach ensures a consistent install experience across indoor/outdoor transitions. That reduces callbacks, speeds activations, and stable field performance for your system.
Comprehensive Support & After-Sales
Our team coordinates tests, line schedules, 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 installation notes so field crews share a unified 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.
- Configuration control so shipped items match agreed requirements every time.
| Area | Scope | Benefit |
|---|---|---|
| Engineering | Specs + pilots | Reduced field issues |
| Testing | Lab trials & 100% test reports | Traceable quality |
| After-sales | Fast replace + RCA | Lower downtime |
Conclusion
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
We deliver customized FTTH drop solutions that pair material choices with validated manufacturing and lab testing. Every reel includes a 100% test report and documented lab trials to support field acceptance in the United States.
A robust production line, including CLX-BPO2 prep assets, 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 customer 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 fiber optic and optic cable shipment with lab validation and responsive support.