Fiber-to-the-Home Cable Production: How the Manufacturing Process Works
Surprising fact: in excess of 70% of new broadband deployments in the U.S. now depend on fiber networks that need high-precision manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment handles end-to-end Fiber cable sheathing line manufacturing, from sourcing brand fibers like Fujikura or Corning® SMF-28e to comprehensive test documentation that guarantee full quality assurance.
Our FTTH drop designs suit overhead, ducted, and direct burial installation, with low-smoke zero-halogen (LSZH), PVC, and polyethylene (PE) jacket options and configurations from 1 to 4 cores. We supply single-mode OS1/OS2 and OM2–OM4 grades plus G.652D and 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 are 4–5 days for orders under 100 km and 7–10 days under 500 km, with an min. order of 1 km and warranty for free replacement on quality issues.
Continue to learn 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 United States projects.
- A range of jacket options and fiber grades fit different install environments.
- Automated lines and machines provide stable quality and stable optical performance.
- Fast lead times, low minimums, and brand fiber options keep procurement predictable.
- Complete reports and after-sales warranty support 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 dedicated manufacturer, Shanghai Weiye OFC Equipment combines specialized equipment with tight material control. We provide customized service and products for single-family and MDU rollouts. Every order comes with 100% quality assurance and full test reports.
Our lab performs high heat, salt-fog, and vibration testing to verify durability. Jacket options include LSZH, PVC, and PE. Designs cover flat bow-type and 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.
- Engineering support for specification reviews, trials, and volume ramp.
- Modern fixtures and calibration minimize variation so every cable meets carrier standards.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, pairing brand fiber choices with rigorous test routines.
Selecting Optical Fiber and Brands
We align fiber draw tower to minimum bend radius, loss, and deployment type. 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 offered to meet procurement standards.
Strength member integration
Strength members employ dielectric FRP or metallic steel wire. FRP is preferred where non-conductive runs are required. Steel wire provides tensile strength for long-span aerial runs and grounding needs.
Jacket Options and Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility, and PE for UV/moisture resistance outdoors. Closed-loop control of extruder temperature and capstan speed keeps line speed stable and critical dimensions.
| Component | FRP | Steel wire |
|---|---|---|
| Primary use | Electrical isolation | High-tension aerial runs |
| Advantage | Light, non-corrosive | Very high tensile strength |
| Installation note | Simple terminations | Bonding/grounding required |
In-Process and Final Testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests verify loss and return loss. Each order includes a full test report and lab results from high heat, 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 provide traceability and compliance for U.S. projects.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment offers a focused portfolio of FTTH drop designs that cover tight indoor routes and exposed aerial spans. Each option combines tested materials with field-termination geometry and consistent optical performance.
The flat bow-type drop keeps a small footprint for risers and conduit. It keeps bend loss low for simple routing in hallways and MDUs.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs use a messenger element to carry tensile loads. Choose dielectric FRP for non-conductive runs or steel messenger when bonding and higher tensile strength are required.
Layouts & Strength Members
We provide dielectric and metallic strength member configurations to meet safety/EMI requirements. Center loose tube and flat unitube types balance crush resistance and Fiber draw tower for fast terminations.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor UV and moisture resilience. Each series is qualified for mechanical and optical quality before shipment.
| Type | Application | Strength member | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting (aerial) | Aerial spans | FRP/Steel | PE |
| Center loose tube | Higher-count builds | Dielectric FRP | LSZH/PE |
| Flat unitube | Low count, quick strip | FRP or steel | LSZH or PE |
Production line equipment that ensures quality and speed
Automation and sensor-driven 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 reduce operator variability.
The CLX-BPO2 auto-stripping machine runs under PLC and photoelectric control. One cycle is about 1.5 seconds, giving ~20 terminals per minute in production.
Auto Cut & Strip Capabilities
The equipment strips LSZH and PVC jackets and trims FRP or steel strength members to precise stub lengths. Pneumatic cylinder actuators provide quick, repeatable motion and minimize downtime.
PLC/photoelectric control for precision and repeatability
PLC logic and photoelectric sensors give exact positioning and closed-loop control. Inline checks feed control charts so operators can adjust drifts before defects grow.
| Feature | Spec | Result |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | High throughput |
| Drive | Cylinder-based | High speed and reliability |
| Materials | LSZH/PVC; FRP/steel | Clean, accurate preps |
| Process control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic loading maintain clean workcells.
- PCPs capture calibration intervals and critical parameters.
- Integrated assets and trained operators support FTTH volume targets without sacrificing 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 deploys the CLX-BPO2 to increase throughput and standardize prep quality. The unit runs at an approximate cycle time of 1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC and photoelectric control enable precise detection and repeatable actuation. That control keeps strip and stub lengths within tight tolerances.
Throughput & Cycle Time
Typical operation speed is 1.5s per cycle. This enables steady throughput under normal production conditions.
Supported jacket and reserved strength lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable jacket strip length from 17.5–35.0 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 cuts FRP/steel strength elements cleanly while protecting adjacent fibers. Custom tooling 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), 50W at 110–220V, and 11 kg mass ease integration into workcells.
- Pneumatic cylinders and PLC/photoelectric control improve line reliability and reduce maintenance downtime.
| Specification | Value | Benefit |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5–35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0 to 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 terminal prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 supports our lines in meeting volume targets without compromising 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 to 4 cores with SM or MM 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 tags.
Jackets, Legends & Branding
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom legends/logos aid inventory/warranty tracking.
Put-Ups, Packaging, and Structures
Standard reel lengths are 1 km, 2 km, and 4 km with custom reels and packaging to suit storage and handling. Choose bow-type flat or self-supporting designs and steel wire or FRP strength members to meet span and isolation needs.
| Option | Typical | Advantage |
|---|---|---|
| Reel length | 1, 2, or 4 km | Less staging, easier reels |
| Jacket | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Design | Bow-type / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and provides docs that lists final specifications for easy on-site QA.
Quality assurance, testing, and documentation
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 runs elevated-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials and assemblies. These tests simulate field stresses for indoor/outdoor applications.
Per-Reel 100% Reports
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.
Traceability & Compliance
Batch records link tests to reels/serials so audits and claims are easy to verify. Documentation follows common customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection reduce field failures and lower warranty events.
- QA packages include spec confirmation and formatted test data for quick review.
- Ongoing trend analysis drive preventive maintenance and improve long-term reliability.
| Test | Purpose | Outcome |
|---|---|---|
| High-temperature | Thermal stability | Validated heat endurance |
| Salt-fog | Corrosion resistance | Outdoor suitability |
| Vibration | Mechanical robustness | 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 vary widely—from about $30 to $1,000 per unit—based on fiber grade, jacket chemistry (LSZH, PVC, PE), reel length, and structural design.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber optic grade, jacket material, and the chosen structure for deployment.
Self-supporting designs and steel members increase material/labor. Custom sheath colors/logos/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.
- Changeovers and special cutters extend lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets across phases.
| Driver | Price impact | Guidance |
|---|---|---|
| Optical 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 |
Lead times, MOQ, and delivery for the United States
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 plan capacity to track your milestones and to maintain on-time delivery.
The service team provides updates/tracking so installation teams can plan arrivals. For compressed schedules, we hold contingency capacity to accelerate 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 put-ups and staging 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 aerial, ducted pull, or direct burial 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 manage sag/tension for long-term reliability.
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 matters.
Direct-buried designs require proper depth control per local codes and moisture-resistant jackets to protect the optic core over time.
Indoor Distribution and ONT
Indoor riser/plenum routes favor LSZH jackets to meet flame and smoke rules. Flat drop profiles strip clean and present controlled 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 prep from the production line reduces install time and reduces scrap.
| Scenario | Key feature | Installer note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Underground duct | Low-friction, crush-resistant | Use pull tape and proper lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow depth/warning tape codes |
| Indoor | LSZH with tight-bend support | Maintain bend radius at penetrations |
Our approach ensures a consistent install experience across indoor/outdoor transitions. That reduces callbacks, faster activations, and stable field performance for your system.
Comprehensive Support & After-Sales
Our team coordinates testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements through approved drawings and pilot builds. We deliver documentation templates and clear installation 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 test reports and traceability to support QA acceptance.
- Round-the-clock availability for status and technical support.
- Warranty with free replacement if any quality problems are confirmed.
- Coordination of line schedules for urgent changes or acceleration requests.
- Config control so shipped items match agreed requirements every time.
| Area | What we do | Benefit |
|---|---|---|
| Tech/Eng | Specs + pilots | Fewer field issues |
| Testing | Lab trials & 100% test reports | Full traceability |
| Service | Fast replace + RCA | 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 includes a 100% test report and documented lab trials to support U.S. field acceptance.
A robust 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 through jacket, printing, and packaging, we balance design and cost to extend service life. Dedicated support covers scheduling/logistics/after-sales so your deployment remains 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 service.