FTTH Drop Cable Production: Step-by-Step Manufacturing Process
Did you know: more than seventy percent of new U.S. broadband builds now depend on fiber networks that require tight manufacturing control to achieve required performance.
Shanghai Weiye OFC Equipment manages complete Fiber cable sheathing line manufacturing, from choosing brand fibers like Fujikura or Corning SMF-28e to comprehensive test documentation that deliver 100% QA.
Our FTTH drop designs are built for overhead, underground, and direct-buried installation, with LSZH, polyvinyl chloride (PVC), and polyethylene (PE) jacket options and arrangements 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 stabilize line speed and maximize repeatability. 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 warranty for free replacement on quality issues.
Keep reading to learn how our materials, tests, and support work together to reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment offers complete production and laboratory testing for U.S. deployments.
- Multiple jacket choices and fiber grades support different install environments.
- Automated lines and machines deliver stable quality and reliable optical performance.
- Fast lead times, low MOQ, and brand fiber options help plan procurement reliably.
- Complete reports and after-sales warranty support product reliability and documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment provides tailored drop solutions with complete test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment combines specialized equipment with stringent material control. We offer custom builds and services for residential and MDU rollouts. Every order comes with 100% quality assurance and complete test reports.
Our lab performs high-temperature, salt-fog, and vibration tests to verify durability. Jacket options include 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.
- Documented line control and in-process checks for auditable shipments.
- Engineering support for specification reviews, trials, and volume ramp.
- Modern fixtures and calibration reduce variability so every cable meets operator standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, combining brand fiber choices with rigorous test routines.
Optical fiber selection and brand options
We select Fiber coloring machine 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 offered to satisfy sourcing standards.
Integrating Strength Members
Strength members employ FRP (dielectric) or galvanized steel wire. FRP is preferred where non-conductivity is necessary. Steel wire provides tensile strength for longer aerial spans and grounding needs.
Jacket extrusion and process control
Jacket options include LSZH for indoor flame safety, PVC for flexibility, and PE for outdoor UV and moisture resistance. Tight process control of temperature and capstan ratios keeps line speed stable and dimensional tolerances.
| Component | FRP | Metallic Steel |
|---|---|---|
| Use case | Non-conductive runs | High-tension aerial runs |
| Key benefit | Lightweight, inert | High strength |
| Installer note | Easier terminations | Requires grounding |
Testing & Verification
Inline geometry/concentricity checks operate in-line. Final optical tests confirm loss and return loss. Each order ships with a full test report and lab results from high heat, salt-spray, and vibration trials to confirm handling for drop terminations and field use.
Typical lead times are 4–5 days for < 100 km and under 500 km in 7–10 days. Lot records and FAI approvals provide traceability and compliance for U.S. programs.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment provides a compact 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 keeps a small footprint for risers/ducts. 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 handle tension. Choose dielectric FRP for non-conductive runs or steel wire when bonding and extra 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 flat unitube types balance crush resistance and fiber secondary coating line for fast terminations.
Indoor/outdoor jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor durability. Each family is qualified for mechanical and optical quality before shipment.
| Type | Best use | Strength element | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting | Aerial spans | Steel wire or FRP | PE |
| Central loose-tube | Higher-count builds | FRP | LSZH/PE |
| Unitube flat | Low-count, easy strip | FRP or steel | LSZH or PE |
Production Assets for Speed and Quality
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and boost throughput for drop patch preparation.
Our production line integrates automated machines that cut and strip drop patch cords to increase output and reduce operator variability.
The CLX-BPO2 automated stripper runs under PLC and photoelectric control. One cycle is about 1.5 seconds, giving ~20 terminals per minute in production.
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 stub lengths. Cylinder-driven actuators provide quick, repeatable motion and low 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 correct trends before out-of-control conditions occur.
| Feature | Spec | Benefit |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Drive | Cylinder-based | High speed and reliability |
| Materials | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Automated waste ejection and ergonomic loading keep the line clean.
- Process control plans document calibration and key parameters.
- Integrated assets and trained operators help meet FTTH volume goals without sacrificing accuracy.
What the CLX-BPO2 Adds
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 raise output and standardize terminal quality. The unit cycles in ~1.5 seconds, yielding about 20 terminal preparations per minute in production.
PLC/photoelectric control deliver exact 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 translates to steady throughput under normal production conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable strip length from 17.5–35.0 mm. Reserved stubs are set between 7.0 and 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. Customized cutters are available for nonstandard sizes to preserve precision.
- Automatic waste ejection and sensor-triggered start cut idle time.
- Compact size (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass simplify cell integration.
- Cylinder-driven motion and closed-loop control boost reliability and reduce maintenance downtime.
| Specification | Value | Why it matters |
|---|---|---|
| Cycle time | ~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 | Meets strength and termination needs |
| Power/Size | 50W @ 110–220V; 40×18×18 cm | Easy integration into existing equipment |
Using this machine, Shanghai Weiye OFC Equipment standardizes prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 supports our lines in meeting volume targets without compromising quality.
Custom Specs for Your FTTH System
Shanghai Weiye OFC Equipment configures each build 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 plus 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 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.
Put-Ups, Packaging, and Structures
Standard reel lengths 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.
| Option | Typical | Benefit |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and reels |
| Sheath | LSZH / PE / PVC | Indoor/Outdoor fit |
| Structure | Flat bow / Self-supporting | Routing and span flexibility |
As a supplier, Shanghai Weiye schedules runs to your plan and provides docs that detail final specs for straightforward QA on site.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item has recorded acceptance data at ship.
Environmental and Mechanical Tests
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.
Per-Reel 100% Reports
Every fiber optic cable includes a 100% test report that records loss, return loss, and key geometry where applicable. Final inspection gates prevent nonconforming shipments before they leave the factory.
Traceability and compliance
Lot/batch records link tests to reels/serials so audits and warranty claims are simple to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- Line checks and final inspection prevent field failures and lower warranty events.
- Quality packages include spec confirmation and formatted test data for quick review.
- Continuous test trends inform preventive maintenance and improve long-term reliability.
| Trial | Why | Outcome |
|---|---|---|
| High-temperature | Thermal stability | Validated heat endurance |
| Salt-fog | Corrosion resistance | Outdoor suitability |
| Mechanical vibration | Resistance to vibration | Improved field reliability |
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 vary widely—from about $30–$1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket chemistry (LSZH, PVC, PE), length, and structural design.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber optic 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 and influence price for short runs.
How Volume & Options Affect Cost
Longer put-ups and larger volumes lower unit cost. Short runs often include setup charges and higher unit prices.
- Line changeovers and custom tooling increase 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.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Optical grade | High impact | Right-size spec to budget |
| Jacket type | Medium impact | Compare LSZH vs. PE for total cost |
| Order length / volume | Large | 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 schedules cut downtime and help control cost when a rollout is underway.
Typical production windows and 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 keep deliveries on time.
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.
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 length and staging plans to choose reel sizes that cut waste and handling. Batch releases can balance inventory with frequent, smaller deliveries to job sites.
Installation Scenarios & Readiness
On-site conditions determine whether a self-supporting span, duct 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 appropriate members to manage sag/tension for long-term stability.
Duct installations work best with low-friction sheaths and crush-resistant builds 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 distribution and ONT termination
Indoor riser and plenum routes prefer LSZH to meet smoke/flame codes. Flat drop profiles strip cleanly and present controlled strength stubs for quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding needs, lightning exposure, and hardware fit. Standardized prep from the production line shortens install time and reduces scrap.
| Scenario | Key design | Installer note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct-buried | PE with moisture barrier | Follow local depth and warning tape rules |
| Interior | 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, speeds activations, and reliable 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 capture through approved drawings and pilot builds. We provide doc templates and clear installation notes so field crews work from the same 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 and technical support.
- Warranty includes free replacement for confirmed quality issues.
- Coordination of line schedules for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed specs consistently.
| Area | What we do | Benefit |
|---|---|---|
| Tech/Eng | Specs + pilots | Fewer field issues |
| QA/Testing | Lab trials & 100% test reports | Full traceability |
| Service | Rapid replacement & root-cause | Minimized downtime |
Final Thoughts
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 ships with a 100% test report and documented 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 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 extend 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 shipment with lab validation and responsive service.