Fiber-to-the-Home Cable Production: Step-by-Step Manufacturing Process
Did you know: over 70% of new U.S. broadband builds now rely on fiber networks that require tight manufacturing control to hit performance targets.
Shanghai Weiye OFC Equipment handles complete compact fiber unit manufacturing, from selecting brand fibers like Fujikura or Corning SMF-28e to complete test reports that deliver 100% QA.
Our drop designs are built for overhead, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and PE jacket options and configurations from 1–4 cores. We provide single-mode OS1/OS2 and multimode OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone sheath colors, and logo printing.
Automated machines and high-precision equipment keep line speed steady and repeatability high. Typical lead times run 4–5 days for orders < 100 km and seven to ten days for < 500 km, with an min. order of 1 km and warranty for free replacement on quality issues.
Read on to see how our materials, tests, and support help reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment delivers end-to-end manufacturing and lab testing for U.S. deployments.
- Multiple jacket choices and optical grades fit different install environments.
- Automated production lines deliver stable quality and stable optical performance.
- Fast lead times, low MOQ, and brand fiber options support reliable procurement planning.
- Comprehensive test reports and after-sales warranty support product reliability and documentation needs.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment provides tailored drop solutions with full test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment pairs purpose-built equipment with tight material control. We provide custom builds and services for residential and MDU rollouts. Every order includes full QA coverage and full test reports.
Our lab conducts high heat, salt spray, and vibration testing to verify durability. Jacket options include LSZH, PVC, and PE. Designs offer bow-type flat and figure-8/self-supporting styles and use brand fibers such as Fujikura and Corning® SMF-28e.
- Controlled production lines and in-process checks for fully auditable shipments.
- Engineering support for specification reviews, trials, and volume ramp.
- Modern fixturing 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 strict test routines.
Selecting Optical Fiber and Brands
We select fiber draw tower to bend radius, attenuation, 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 meet procurement standards.
Integrating Strength Members
Strength members use dielectric FRP or galvanized steel wire. FRP is preferred where non-conductivity is necessary. Steel wire adds tensile strength for long-span aerial runs and bonding/grounding needs.
Jacket extrusion and process control
Jacket options include LSZH for indoor flame safety, PVC for flexibility, and PE for UV/moisture resistance outdoors. Tight process control of temperature and capstan ratios keeps line speed stable and dimensional tolerances.
| Component | FRP | Steel wire |
|---|---|---|
| Primary use | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Light, non-corrosive | 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 loss and return loss. Each order includes 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 4–5 days for < 100 km and 7–10 days for < 500 km. Lot records and first-article approvals support traceability and compliance for U.S. projects.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment offers a focused portfolio of drop designs that suit both tight indoor routes and exposed aerial spans. Each option combines tested materials with field-termination geometry and consistent optical performance.
The bow-type flat drop cable keeps a small footprint for risers/ducts. It keeps bend loss low for easy routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs use a messenger element to handle tension. Choose dielectric FRP for non-conductive runs or steel wire when bonding/grounding and higher tensile strength are required.
Layouts & Strength Members
We provide 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 family is qualified for mechanical/optical performance before shipment.
| Type | Application | Strength member | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | FRP (dielectric) | LSZH |
| Self-supporting | Overhead spans | FRP/Steel | PE |
| Center loose tube | Higher-count builds | FRP | LSZH or PE |
| Flat unitube | Low count, quick strip | FRP/Steel | LSZH/PE |
Production line equipment that ensures quality and speed
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and boost throughput for patch cord prep.
Our production line integrates automated machines that cut and strip drop patch cords to raise throughput and reduce operator variability.
The CLX-BPO2 auto-stripping machine runs under PLC and photoelectric control. One cycle is ~1.5 s, giving ~20 terminals per minute in production.
Automated cutting and stripping for drop cable patch cords
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 low downtime.
Closed-Loop Control for Repeatability
PLC logic and photoelectric sensors give exact positioning and closed-loop control. Inline checks update SPC charts so operators can correct trends before defects grow.
| Feature | Spec | Benefit |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | High throughput |
| Drive | Cylinder-based | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic loading keep the line clean.
- Process control plans capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets without compromising accuracy.
CLX-BPO2 Capabilities on Our Line
The CLX-BPO2 provides industrial-grade strip/trim to our line, cutting cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output and standardize terminal 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 helps keep strip lengths and reserved strength stubs within tight tolerances.
Line Speed
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 17.5–35.0 mm. Reserved stubs are adjustable from 7.0–11.0 mm to fit 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 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 ease integration into workcells.
- Pneumatic cylinders and PLC/photoelectric control boost reliability and lower maintenance interruptions.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5–35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0–11.0 mm | Supports termination strength |
| Power & size | 110–220V, 50W; 40×18×18 cm | Easy integration into existing equipment |
Using this machine, Shanghai Weiye OFC Equipment standardizes terminal prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 supports our lines in meeting volume targets without sacrificing quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures every order 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, and OM2–OM4 along with 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 put-ups are 1/2/4 km with custom reels and packaging to suit storage and handling. Choose bow-type flat or self-supporting designs and FRP or steel members to fit span and isolation requirements.
| Choice | Typical | Benefit |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Simpler staging and reels |
| Jacket | LSZH, PE, PVC | Indoor/Outdoor fit |
| Design | Bow-type / Self-supporting | Routing and span flexibility |
As a supplier, Shanghai Weiye schedules runs to your plan and delivers documentation that detail final specs for straightforward QA on site.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item has recorded acceptance data at ship.
High-temperature, salt spray, and vibration laboratory testing
Our lab conducts elevated-temperature exposure, salt fog corrosion, and vibration tests to qualify materials/assemblies. These tests simulate field stresses for indoor/outdoor applications.
Full Test Reports for Every Reel
Every fiber optic cable ships with a 100% test report that logs attenuation, return loss, and geometry where applicable. Final inspection 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 warranty claims are simple 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.
- Quality packages include specifications confirmation and formatted test data for quick review.
- Continuous test trends inform preventive maintenance and improve long-term reliability.
| Test | Purpose | Result |
|---|---|---|
| Heat exposure | Thermal stability | Pass at target temperature |
| Salt spray | Corrosion resistance | Qualified for outdoor use |
| Mechanical vibration | Resistance to vibration | Reduced field failures |
FTTH Drop Cable Pricing & Cost Drivers
Budgeting for a drop run begins with fiber/jacket selection 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 design structure.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber grade, sheath material, and the chosen structure for deployment.
Self-supporting designs and steel strength elements raise material and labor input. Custom colors, logos, and print legends add setup and influence price for short runs.
Length/Volume/Customization Impact
Longer reels and higher volume orders reduce unit cost. Short runs often carry setup fees and higher per-unit charges.
- Changeovers and special cutters increase lead time and add to 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.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Optical grade | High impact | Balance spec vs. budget |
| Sheath material | Medium impact | Evaluate LSZH vs PE |
| Length/Volume | Large | Consolidate runs to cut unit cost |
Logistics for the U.S.
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews and sites. Predictable windows reduce downtime and control costs when a rollout is underway.
Scheduling & Capacity Planning
Typical production windows run 4–5 days for orders under 100 km and 7–10 days for orders under 500 km. We plan 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 tight schedules, we hold contingency capacity to pull in critical-path orders.
Minimum order quantity and why it matters
The MOQ is one kilometer. This reflects line setup such as wire/die adjustments that consume start-up material and scrap.
We review your put-ups and staging to select reels to reduce waste/handling. Staggered batches can balance inventory with more frequent small-site deliveries.
Installation readiness and application scenarios
On-site conditions dictate whether a self-supporting aerial, ducted pull, or direct burial is the best fit for a project.
Aerial vs Duct vs Direct-Buried
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with appropriate members to manage sag/tension for long-term reliability.
Duct installations work best with low-friction sheaths and crush-resistant constructs so pulling avoids fiber damage. PE jackets are common 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 Riser/Plenum & ONT
Indoor riser/plenum routes favor LSZH jackets to meet smoke/flame codes. Flat drop profiles strip cleanly and present controlled stubs for quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding requirements, lightning risk, and hardware compatibility. Standardized prep from the production line shortens install time and reduces scrap.
| Deployment | Key feature | Field note |
|---|---|---|
| Aerial | Self-supporting (steel/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 local depth and warning tape rules |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at 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 through approved drawings and pre-production builds. We deliver documentation templates and clear install 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 with free replacement if any quality problems are confirmed.
- Coordination of line schedules for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed specs consistently.
| Support area | Scope | Benefit |
|---|---|---|
| Engineering | Spec review & pre-production builds | Reduced field issues |
| QA/Testing | Lab + 100% reports | Traceable quality |
| Service | Rapid replacement & root-cause | Lower downtime |
Wrap-Up
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
We provide custom FTTH drops that pair material choices with validated manufacturing and lab testing. Every reel includes a 100% test report and documented trials to support U.S. field acceptance.
A robust production line, including CLX-BPO2 prep assets, reduces variability and speeds turnaround. Our equipment and machines standardize strip and stub lengths so installers get consistent results at turn-up.
From fiber selection to 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 stays on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every shipment with lab validation and responsive support.
