Fiber-to-the-Home Cable Production: Manufacturing Process Explained
Surprising fact: in excess of seventy percent of new broadband deployments in the U.S. now depend on fiber networks that need precise manufacturing to achieve required performance.
Shanghai Weiye OFC Equipment manages complete SZ stranding line manufacturing, from selecting brand fibers like Fujikura® or Corning® SMF-28e to final test reports that deliver 100% QA.
Our drop designs fit aerial, ducted, and direct-buried installation, with low-smoke zero-halogen (LSZH), PVC, and PE jacket options and core counts from 1 to 4 cores. We provide single-mode OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and logo printing.
Automated machines and high-precision equipment stabilize line speed and keep repeatability high. Typical lead times are four to five 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, testing, and support combine to lower lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment delivers complete production and laboratory testing for U.S. deployments.
- Multiple jacket choices and fiber grades support varied installation environments.
- Automated lines and machines deliver stable quality and reliable optical performance.
- Quick lead times, low minimums, and recognized brand fibers keep procurement predictable.
- Complete reports and after-sales warranty back product reliability and compliance documentation needs.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment delivers customized drop cables with full test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment combines specialized equipment with tight material control. We offer custom builds and services for residential and MDU rollouts. Every order includes 100% quality assurance and complete test reports.
Our lab runs high heat, salt spray, and vibration testing to verify durability. Jacket options cover LSZH, PVC, and PE. Designs include bow-type flat and figure-8/self-supporting styles and support brand fibers such as Fujikura and Corning® SMF-28e.
- Controlled production lines and production checks for auditable shipments.
- Technical support for requirements, pilots, and scaling.
- Modern fixturing and calibration minimize variation so every cable meets operator standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, combining brand fiber choices with rigorous test routines.
Optical fiber selection and brand options
We match Fiber coloring machine to bend radius, attenuation, 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 available to meet procurement standards.
Strength Member Options
Strength members employ dielectric FRP or galvanized steel wire. FRP is ideal where non-conductive runs are required. Steel wire adds tensile strength for long-span aerial runs and bonding/grounding needs.
Extrusion & Process Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility and ease of handling, and PE for outdoor UV and moisture resistance. Closed-loop control of temperature and capstan ratios keeps line speed stable and dimensional tolerances.
| Member | Dielectric FRP | Steel wire |
|---|---|---|
| Primary use | Electrical isolation | High-tension aerial runs |
| Key benefit | Lightweight, inert | High strength |
| Installation note | Simple terminations | Requires grounding |
In-Process and Final Testing
Inline geometry and concentricity checks run during manufacturing. Final optical tests verify attenuation 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 under 100 km in 4–5 days and 7–10 days for < 500 km. Lot records and FAI approvals provide traceability and compliance for U.S. programs.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment offers a focused portfolio of FTTH drop designs that cover tight indoor routes and exposed aerial spans. Each option pairs tested materials with geometry tuned for field termination and consistent optical performance.
The flat bow-type drop minimizes footprint for risers/ducts. It reduces bend loss for easy routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs use a support messenger to handle tension. Choose FRP (dielectric) 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 match safety and EMI rules. Center loose tube and flat unitube types balance crush resistance and Fiber coloring machine for fast terminations.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor UV and moisture resilience. Each series is qualified for mechanical and optical quality before shipment.
| Type | Application | Strength element | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting (aerial) | Overhead spans | Steel wire or FRP | Polyethylene |
| Central loose-tube | Higher-count builds | FRP | LSZH or PE |
| Unitube flat | Low count, quick strip | FRP/Steel | LSZH/PE |
Production line equipment that ensures quality and speed
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for patch cord prep.
Our production line uses automated machines that cut and strip drop patch cords to increase output 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 and PVC jackets and trims FRP or steel strength members to precise stub lengths. Cylinder-driven actuators provide quick, repeatable motion and minimize downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors deliver precise positioning and closed-loop control. Inline checks update SPC charts so operators can adjust drifts before defects grow.
| Item | Capability | Result |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | High throughput |
| Drive | Pneumatic cylinders | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Automated waste ejection and ergonomic loading keep the line clean.
- PCPs 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 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 prep quality. The unit runs at an approximate cycle time of 1.5 seconds, yielding about 20 terminal preparations 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.
Line Speed
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 strips LSZH and PVC jackets 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.
FRP & Steel Member Handling
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Custom tooling are offered for nonstandard sizes to maintain precision.
- Auto-eject scrap and sensor-triggered start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg weight ease integration into workcells.
- Cylinder-driven motion and closed-loop control boost reliability and lower maintenance interruptions.
| Specification | Rating | Benefit |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | Supports high-volume runs |
| Strip lengths (A) | 17.5–35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0–11.0 mm | Meets strength and termination needs |
| 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 get drop parts install-ready. The CLX-BPO2 helps our production lines meet volume goals without sacrificing quality.
Custom Specs for Your FTTH System
Shanghai Weiye OFC Equipment configures every order 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, 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 legends/logos aid inventory/warranty tracking.
Lengths, Packaging & Special Builds
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 meet span and isolation needs.
| Choice | Typical | Advantage |
|---|---|---|
| Length | 1 / 2 / 4 km | Simpler staging and reels |
| Jacket | LSZH / PE / PVC | Indoor/Outdoor fit |
| Design | Flat bow / Self-supporting | Flexible routing/span |
As a supplier, Shanghai Weiye aligns runs to your schedule and provides docs that lists final specifications for easy on-site QA.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment builds checkpoints into production 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 and outdoor use.
Full Test Reports for Every Reel
Every fiber optic cable includes a 100% test report that logs attenuation, return loss, and geometry where applicable. Final QC gates prevent nonconforming shipments before they leave the factory.
Audit Trail and Compliance
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.
- Line checks and final inspection reduce field failures and lower warranty events.
- QA packages include specifications confirmation and formatted data for quick review.
- Ongoing trend analysis inform preventive maintenance and raise long-term reliability.
| Trial | Purpose | Outcome |
|---|---|---|
| Heat exposure | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion robustness | Qualified for outdoor use |
| Vibration | Mechanical robustness | Reduced field failures |
Pricing and cost drivers for FTTH drop cable
Budget planning for a drop starts with fiber and jacket choices and is shaped by volume and customization.
Typical prices range broadly—from about $30–$1,000 per unit—based on fiber grade, jacket material, reel length, and design structure.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber grade, sheath material, and the structural type chosen for deployment.
Self-supporting structures and steel members raise material and labor input. Custom colors, logos, and print legends add setup 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 include setup charges and higher per-unit charges.
- Changeovers and special cutters 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 over phases.
| Driver | Price impact | Recommendation |
|---|---|---|
| Optical grade | High impact | Right-size spec to budget |
| Sheath material | Medium impact | Evaluate LSZH vs PE |
| Order length / volume | High impact | Consolidate runs to cut unit cost |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align staffing and sites. Predictable windows cut downtime and control costs when a rollout is underway.
Production Windows & Capacity
Typical production windows are 4–5 days for < 100 km and 7–10 days for < 500 km. We plan capacity to match your rollout milestones and to keep deliveries on time.
The service team provides updates/tracking so installation teams can plan arrivals. For tight schedules, we reserve contingency capacity to pull in critical-path orders.
MOQ and Rationale
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 more frequent small-site deliveries.
Where and How to Deploy
Site conditions dictate whether a self-supporting aerial, duct pull, or direct-buried run is the right choice for a project.
Aerial vs Duct vs Direct-Buried
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with correct strength members to manage sag/tension for long-term stability.
Duct installations perform best with low-friction jackets 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 barriers to protect the fiber core long-term.
Indoor Riser/Plenum & ONT
Indoor riser/plenum routes prefer LSZH to meet smoke/flame codes. Flat drop profiles strip cleanly and present controlled strength stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware fit. Standardized prep from the production line shortens install time and minimizes scrap.
| Deployment | Key design | Installer note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Underground duct | Low-friction jacket, crush resistance | Use pull tape + lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow depth/warning tape codes |
| Interior | LSZH jacket, tight bend support | Maintain bend radius at wall 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 avoid surprises in deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements capture through approved drawings and pre-production builds. We deliver documentation 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 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 specs consistently.
| Support area | Scope | Benefit |
|---|---|---|
| Engineering | Spec review & pre-production builds | Fewer field issues |
| Testing | Lab trials & 100% test reports | Traceable quality |
| Service | Fast replace + RCA | Lower downtime |
Wrap-Up
Select Shanghai Weiye OFC Equipment for custom drops, quick lead times, and full traceability.
We deliver customized FTTH drop solutions that combine materials with validated manufacturing and lab tests. 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 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 performance and cost to extend 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 fiber optic and optic cable shipment with lab validation and responsive service.