Fiber-to-the-Home Cable Production: Step-by-Step Manufacturing Process
Did you know: over seventy percent of new U.S. broadband builds now rely on fiber networks that require precise manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment manages complete Fiber cable sheathing line manufacturing, from selecting brand fibers like Fujikura® or Corning® SMF-28e to complete test reports that deliver 100% QA.
Our drop cable designs are built for overhead, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and polyethylene (PE) jacket options and core counts from 1–4 cores. We offer single-mode OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone-matched sheath colors, and logo printing.
Automated machines and high-precision equipment keep line speed steady and keep repeatability high. Typical lead times run 4–5 days for orders < 100 km and seven to ten days under 500 km, with an MOQ of 1 km and free-replacement warranty for quality problems.
Continue 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 complete production and laboratory testing for United States projects.
- A range of jacket options and optical grades fit different install environments.
- Automated production lines deliver stable quality and stable optical performance.
- Quick lead times, low minimums, and recognized brand fibers support reliable procurement planning.
- Comprehensive test reports and warranty back product reliability and compliance documentation needs.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment delivers customized drop cables with complete test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment pairs purpose-built equipment with tight material control. We offer customized service and products for residential and MDU rollouts. Every order includes 100% quality assurance and full test reports.
Our lab performs high heat, salt-fog, and vibration testing to verify durability. Jacket options cover LSZH, PVC, and PE. Designs include flat bow-type and figure-8/self-supporting styles and use brand fibers such as Fujikura and Corning SMF-28e.
- Documented line control and in-process checks for shipments with audit trails.
- Technical support for requirements, pilots, and scaling.
- Modern fixtures and calibration reduce variability so every cable meets carrier standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, combining brand fiber choices with disciplined test flows.
Selecting Optical Fiber and Brands
We select FTTH cable production line to 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 employ FRP (dielectric) or galvanized steel wire. FRP is preferred where non-conductive runs are required. Steel wire adds tensile strength for longer aerial spans and grounding needs.
Jacket Options and Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility and ease of handling, and PE for UV/moisture resistance outdoors. Tight process control of extruder temperature and capstan speed keeps line speed stable and critical dimensions.
| Member | Dielectric FRP | Metallic Steel |
|---|---|---|
| Primary use | Non-conductive runs | Aerial spans, high tensile |
| Key benefit | Light, non-corrosive | High strength |
| Installer note | Simple terminations | Bonding/grounding required |
Inline and final testing
Inline geometry/concentricity checks operate in-line. Final optical tests verify attenuation and reflectance. Each order ships with a full test report and lab results from high-temperature, salt fog, 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 FAI approvals support traceability and compliance for U.S. programs.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment offers a focused portfolio of drop designs that cover tight indoor routes and exposed aerial spans. Each option combines tested materials with field-termination geometry and stable optical performance.
The bow-type flat drop cable minimizes footprint for risers and conduit. It keeps bend loss low for easy routing in hallways and MDUs.
Aerial Self-Supporting Options
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 higher tensile strength are required.
Strength member and core layouts
We offer dielectric and metallic strength member configurations to match safety and EMI rules. Central loose-tube and flat unitube types balance crush resistance and compact fiber unit for fast terminations.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each family is qualified for mechanical/optical performance before shipment.
| Type | Best use | Strength element | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | Dielectric FRP | LSZH |
| Self-supporting | Overhead spans | FRP/Steel | Polyethylene |
| Central loose-tube | Higher-count builds | FRP | LSZH/PE |
| Flat unitube | Low-count, easy strip | FRP or steel | LSZH or PE |
Production line equipment that ensures quality and speed
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and increase throughput for patch cord prep.
Our production line integrates automated machines that cut/strip drop cords to raise throughput and reduce operator variability.
The CLX-BPO2 auto-stripping machine uses PLC + photoelectric control. One cycle is about 1.5 seconds, giving real-world speeds near 20 terminal operations per minute.
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.
PLC & Photoelectric for Precision
PLC logic and photoelectric sensors deliver precise positioning and feedback control. Inline checks update SPC charts so operators can adjust drifts before defects grow.
| Feature | Capability | 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 |
| Process control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Automated waste ejection and ergonomic feeders keep the line clean.
- Process control plans document calibration and key parameters.
- Integrated assets and trained operators support FTTH volume targets without sacrificing accuracy.
What the CLX-BPO2 Adds
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, cutting cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment deploys the CLX-BPO2 to raise output and standardize prep quality. The unit runs at an approximate cycle time of 1.5 seconds, producing around 20 preps per minute in production.
PLC and photoelectric control enable precise detection and repeatable actuation. That control keeps strip and stub lengths within tight tolerances.
Line Speed
Typical operation speed is ~1.5 seconds per cycle. This converts 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 match common termination hardware.
FRP & Steel Member Handling
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Customized cutters are available for non-standard cross-sections to maintain precision.
- Auto-eject scrap and sensor-triggered start cut idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight simplify cell integration.
- Pneumatic cylinders and closed-loop control boost reliability and lower maintenance interruptions.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5–35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0–11.0 mm | Meets strength and termination needs |
| Power/Size | 50W @ 110–220V; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes prep so field teams get drop parts install-ready. The CLX-BPO2 supports our lines in meeting volume targets without sacrificing quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures every order to fit 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 SM or MM fiber. Options include OS1, OS2, and OM2–OM4 along with G.652D/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 to suit route and safety requirements. Custom legends/logos support inventory and warranty tracking.
Lengths, Packaging & Special Builds
Standard put-ups are 1 km, 2 km, and 4 km with tailored reels and packaging to fit storage/handling. Choose bow-type flat or self-supporting designs and FRP or steel members to meet span and isolation needs.
| Choice | Typical | Benefit |
|---|---|---|
| Reel 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 manufacturer, Shanghai Weiye schedules runs to your plan and provides docs that detail final specs for easy on-site QA.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item ships with recorded acceptance data.
Environmental and Mechanical Tests
Our lab runs high-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials and assemblies. These tests simulate field stresses for indoor/outdoor applications.
Full Test Reports for Every Reel
Every fiber optic cable includes 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.
Audit Trail and Compliance
Lot/batch records tie test data to reels and 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 reduce field failures and lower warranty events.
- Quality packages include specifications confirmation and formatted test data for quick review.
- Continuous test trends inform preventive maintenance and raise long-term reliability.
| Test | Purpose | Result |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion robustness | Outdoor suitability |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
Cost Drivers and Pricing
Budget planning for a drop begins with fiber/jacket selection and is shaped by volume and customization.
Typical prices range broadly—from about $30–$1,000 per unit—based on fiber grade, jacket chemistry (LSZH, PVC, PE), length, and design structure.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber grade, sheath material, and the chosen structure for deployment.
Self-supporting designs and steel members raise material and labor input. Custom colors, logos, and print legends add setup time and impact pricing on small runs.
Order length, volume, and customization impact on price
Longer reels and higher volume orders reduce unit cost. Short runs often carry setup fees and higher unit prices.
- Line changeovers and custom tooling extend lead time and add cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets over phases.
| Factor | Effect on price | Guidance |
|---|---|---|
| Fiber grade | High impact | Right-size spec to budget |
| Jacket type | Medium | Compare LSZH vs. PE for total cost |
| Order length / volume | High impact | Consolidate where possible |
Lead times, MOQ, and delivery for the United States
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align staffing and sites. Predictable schedules reduce downtime and help control cost when a rollout is underway.
Scheduling & Capacity Planning
Typical production windows are 4–5 days for < 100 km and 7–10 days for < 500 km. We schedule line capacity to match your rollout milestones and to maintain on-time delivery.
The service team provides updates/tracking so installation teams know when reels arrive. For compressed schedules, we hold contingency capacity to accelerate critical-path orders.
Why MOQ Matters
The MOQ is 1 km. This reflects setup needs such as wire/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. Staggered batches can balance inventory holding with more frequent small-site deliveries.
Installation Scenarios & Readiness
Site conditions dictate whether a self-supporting aerial, ducted pull, or direct-buried run is the best fit for a project.
Deployment Considerations
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with correct strength members to control sag and tension for long-term reliability.
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 and plenum routes favor LSZH jackets to meet flame and smoke rules. Flat drop cable forms strip cleanly and present controlled stubs for fast ONT terminations.
We guide the choice of steel or FRP (dielectric) strength members based on bonding requirements, lightning risk, and hardware fit. Standardized line prep reduces install time and reduces scrap.
| Deployment | Key feature | Field note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Underground duct | Low-friction, crush-resistant | 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, faster activations, and stable field performance for your system.
Comprehensive Support & After-Sales
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 pre-production builds. We provide doc templates and clear installation notes so field crews work from the same plan.
After-sales service includes fast response, RCA, and corrective action. All products ship with full reports and traceability to support QA acceptance.
- Round-the-clock availability for status and technical support.
- Warranty includes free replacement for confirmed quality issues.
- Schedule coordination for expedites and urgent changes.
- Config control so shipped items match agreed specs consistently.
| Support area | What we do | Outcome |
|---|---|---|
| Tech/Eng | Specs + pilots | Fewer field issues |
| QA/Testing | Lab trials & 100% test reports | Full traceability |
| After-sales | Rapid replacement & root-cause | Minimized downtime |
Conclusion
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 includes a 100% test report and documented trials to support field acceptance in the United States.
A robust production line, including CLX-BPO2-enabled prep machines, cuts variability and shortens 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 customer support guides scheduling, logistics, and after-sales care so your deployment stays on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with laboratory validation and responsive service.