FTTH Drop Cable Production: Manufacturing Process Explained
Quick fact: more than 70% of new U.S. broadband builds now use fiber networks that require high-precision manufacturing to achieve required performance.
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), PVC, and PE jacket options and core counts from 1 to 4 cores. We supply OS1/OS2 and multimode OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automation and high-precision equipment keep line speed steady and keep repeatability high. Typical lead times run four to five days for orders < 100 km and 7–10 days under 500 km, with an MOQ of 1 km and free-replacement warranty for quality problems.
Continue to understand how materials, testing, and support work together to 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.
- A range of jacket options and fiber grades support varied installation environments.
- Automated production lines ensure consistent quality and reliable optical performance.
- Fast lead times, low MOQ, and recognized brand fibers keep procurement predictable.
- Complete reports and warranty support product reliability and compliance documentation needs.
Specialized 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 dedicated manufacturer, Shanghai Weiye OFC Equipment pairs specialized equipment with stringent material control. We provide customized service and products for residential/MDU deployments. Every order includes full QA coverage and full test reports.
Our lab performs high-temperature, salt-fog, and vibration testing to verify durability. Jacket options include LSZH, PVC, and PE. Designs offer bow-type flat and self-supporting styles and support brand fibers such as Fujikura and Corning SMF-28e.
- Documented line control and in-process checks for auditable shipments.
- Technical support for requirements, pilots, and scaling.
- Modern fixturing and calibration reduce variability so every cable matches operator specs.
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 draw tower to bend radius, loss, and deployment type. Options include OS1/OS2 and OM2–OM4 and ITU-T G.652D, G.657.A1/A2. Brand fibers such as Fujikura and Corning SMF-28e are offered to satisfy sourcing 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 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 outdoor UV and moisture resistance. Closed-loop control of temperature and capstan ratios keeps line speed stable and critical dimensions.
| Member | Dielectric FRP | Steel wire |
|---|---|---|
| Primary use | Electrical isolation | Aerial spans, high tensile |
| Advantage | Lightweight, inert | Very high tensile strength |
| Installation note | Simple terminations | Bonding/grounding required |
Testing & Verification
Inline geometry/concentricity checks run during manufacturing. Final optical tests confirm loss and reflectance. Each order ships with a full test report and lab results from high-temperature, salt-spray, and vibration trials to qualify field handling and drop terminations.
Typical lead times are 4–5 days for < 100 km and under 500 km in 7–10 days. Lot records and FAI 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 fit indoor risers and long aerial runs. Each option pairs tested materials with geometry tuned for field termination and stable optical performance.
The bow-type flat drop cable keeps a small footprint for risers and conduit. It reduces bend loss for easy routing in hallways and MDUs.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs include a support messenger to handle tension. Choose FRP (dielectric) for non-conductive runs or steel messenger when bonding/grounding and extra tensile strength are required.
Core Layouts and 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 ribbone line for fast terminations.
Indoor/outdoor jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor durability. Each series is validated for mechanical and optical quality before shipment.
| Design | Application | Strength member | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting (aerial) | Aerial spans | FRP/Steel | PE |
| Central loose-tube | Higher fiber counts | FRP | LSZH or PE |
| Flat unitube | Low-count, easy strip | FRP/Steel | LSZH or PE |
Production Assets for Speed and Quality
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for patch cord prep.
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/steel members to precise stub lengths. Cylinder-driven actuators provide quick, repeatable motion and low downtime.
Closed-Loop Control for Repeatability
PLC logic and photoelectric sensors give exact positioning and feedback control. Inline checks update SPC charts so operators can adjust drifts before defects grow.
| Feature | Capability | Result |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Drive | Pneumatic cylinders | High speed and reliability |
| Materials | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Process control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Automated waste ejection and ergonomic loading maintain clean workcells.
- PCPs capture calibration intervals and critical parameters.
- Integrated assets and trained operators help meet FTTH volume goals without compromising accuracy.
CLX-BPO2 auto-stripping machine capabilities in 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 increase throughput 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 deliver exact detection and repeatable motion. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Throughput & Cycle Time
Typical operation speed is 1.5s per cycle. This converts to steady throughput under continuous line conditions.
Jacket Strip & Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable strip length from 17.5 to 35.0 mm. Reserved stubs are adjustable from 7.0–11.0 mm to match common termination hardware.
Handling FRP and steel wire strength members
The machine cleanly cuts FRP and steel wire strength elements while protecting neighboring fibers. Custom tooling are offered for nonstandard sizes to maintain precision.
- Auto-eject scrap and sensor-triggered start cut idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass simplify cell integration.
- Pneumatic cylinders and closed-loop control improve line reliability and lower maintenance interruptions.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | Supports high-volume runs |
| Strip lengths (A) | 17.5 to 35.0 mm | Fits common connector processes |
| Stub (B) | 7.0 to 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 helps our production lines meet volume goals without compromising quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures every order to meet your network requirements and simplify field rollout. We pair concise options with predictable manufacturing windows so your teams receive ready-to-install products.
Choose 1–4 core designs with single-mode or multimode fiber. Options include OS1, OS2, and OM2–OM4 plus G.652D and G.657 variants to match your optics and connector plans.
We Pantone-match sheath colors for quick field identification and consistent asset tags.
Jacket materials, print legends, and branding
Select LSZH, PVC, or PE jackets to suit route and safety requirements. Custom print legends and logos support inventory and warranty tracking.
Lengths, Packaging & Special Builds
Standard reel lengths are 1/2/4 km with tailored reels and packaging to fit storage/handling. Choose flat bow-type or self-supporting and FRP or steel members to meet span and isolation needs.
| Option | Typical | Benefit |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Less staging, easier reels |
| Sheath | LSZH / PE / PVC | Indoor/Outdoor fit |
| Structure | Bow-type / Self-supporting | Routing and span flexibility |
As a supplier, Shanghai Weiye schedules runs to your plan and delivers documentation that lists final specifications for easy on-site QA.
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 runs high-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials/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 inspection gates stop nonconforming items before they leave the factory.
Audit Trail 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 accelerate approvals and receiving inspection.
- Line checks and final inspection reduce field failures and cut warranty events.
- Quality packages include specifications confirmation and formatted test data for quick review.
- Ongoing trend analysis inform preventive maintenance and improve long-term reliability.
| Trial | Purpose | Outcome |
|---|---|---|
| High-temperature | Thermal stability | Validated heat endurance |
| Salt spray | Corrosion resistance | Qualified for outdoor use |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
FTTH Drop Cable Pricing & Cost Drivers
Budgeting for a drop run starts with fiber and jacket choices and is shaped by volume and customization.
Typical prices range broadly—from about $30 to $1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket material, length, and structural design.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, sheath material, and the structural type chosen for deployment.
Self-supporting structures and steel strength elements increase material/labor. Custom sheath colors/logos/legends add setup time and impact pricing on small runs.
Length/Volume/Customization Impact
Longer reels and higher volume orders lower unit cost. Small quantities often include setup charges and higher per-unit charges.
- 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.
- Framework agreements and indexed pricing stabilize budgets across phases.
| Factor | Price impact | Guidance |
|---|---|---|
| Fiber grade | High impact | Balance spec vs. budget |
| Sheath material | 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 crews and sites. Predictable windows cut downtime and control costs when a rollout is underway.
Scheduling & Capacity Planning
Typical production windows are 4–5 days for < 100 km and 7–10 days for orders under 500 km. We plan 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 reserve 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. Batch releases can balance inventory holding with frequent, smaller deliveries to job sites.
Installation Scenarios & Readiness
On-site conditions determine whether a self-supporting span, duct pull, or direct burial 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 control sag and tension for long-term stability.
Duct installations work best with low-friction sheaths and crush-resistant constructs so pulling avoids fiber damage. 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 barriers to protect the fiber core long-term.
Indoor riser/plenum distribution and ONT termination
Indoor riser and plenum routes prefer LSZH 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 prep from the production line reduces install time and reduces scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct burial | PE with moisture barrier | Follow local depth and warning tape rules |
| Indoor | LSZH with tight-bend support | Maintain bend radius at wall 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.
Support from Spec to Service
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 pilot builds. We provide doc templates and clear installation notes so field crews share a unified plan.
After-sales service includes fast response, RCA, and corrective action. All products ship with full reports and traceability to help QA acceptance.
- 24/7 availability for status updates and technical guidance.
- Warranty with free replacement if any quality problems are confirmed.
- Schedule coordination for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed requirements every time.
| Area | What we do | Benefit |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Reduced field issues |
| QA/Testing | Lab trials & 100% test reports | Full traceability |
| After-sales | Fast replace + RCA | 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 lab trials to support field acceptance in the United States.
A hardened production line, including CLX-BPO2-enabled prep machines, reduces variability and shortens turnaround. Our equipment set 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 maximize service life. Dedicated customer support guides scheduling, logistics, and after-sales care so your deployment remains on plan.
Contact Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with laboratory validation and responsive support.