FTTH Drop Cable Production: Step-by-Step Manufacturing Process
Surprising fact: in excess of seventy percent of U.S. broadband rollouts now rely on fiber networks that need tight manufacturing control to achieve required performance.
Shanghai Weiye OFC Equipment runs end-to-end fiber secondary coating line manufacturing, from sourcing brand fibers like Fujikura or Corning SMF-28e to complete test reports that deliver 100% QA.
Our drop cable designs fit aerial, underground, and direct burial installation, with LSZH, polyvinyl chloride (PVC), and PE jacket options and configurations from 1–4 cores. We supply OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and ITU-T G.657 variants, Pantone sheath colors, and logo printing.
Automation and precision equipment keep line speed steady and repeatability high. Typical lead times are 4–5 days for orders < 100 km and 7–10 days under 500 km, with an min. order of 1 km and warranty for free replacement on quality issues.
Read on to see how materials, testing, and support combine to lower lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment provides full manufacturing with lab validation for U.S. deployments.
- A range of jacket options and fiber grades support different install environments.
- Automated lines and machines deliver stable quality and stable optical performance.
- Fast lead times, low MOQ, and brand fiber options support reliable procurement planning.
- Comprehensive test reports and warranty back product reliability and compliance documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment provides customized drop cables with complete test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment combines purpose-built equipment with stringent material control. We offer customized service and products for residential/MDU deployments. Every order comes with 100% quality assurance and full test reports.
Our lab conducts high-temperature, salt-fog, and vibration testing to validate durability. Jacket options cover LSZH, PVC, and PE. Designs offer flat bow-type and self-supporting styles and use brand fibers such as Fujikura and Corning SMF-28e.
- Controlled production lines and production checks for shipments with audit trails.
- Technical support for specs, trials, and ramp to volume.
- Modern fixturing and calibration reduce variability so every cable matches operator specs.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are built around network requirements, pairing brand fiber choices with disciplined test flows.
Optical fiber selection and brand options
We select Fiber coloring machine to bend radius, loss, and deployment type. Options include OS1, OS2, 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 meet procurement standards.
Integrating Strength Members
Strength members employ dielectric FRP or metallic steel wire. FRP is preferred where non-conductivity is necessary. Steel wire provides tensile strength for long-span aerial runs and bonding/grounding needs.
Extrusion & Process Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility and ease of handling, and PE for outdoor UV and moisture resistance. Closed-loop control of extruder temperature and capstan speed stabilizes line speed and critical dimensions.
| Member | FRP | Metallic Steel |
|---|---|---|
| Use case | Electrical isolation | High-tension aerial runs |
| Key benefit | Lightweight, inert | High strength |
| Installation note | Easier terminations | Bonding/grounding required |
Inline and final testing
Inline geometry and concentricity checks operate in-line. Final optical tests verify attenuation and reflectance. 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. Material lot records and first-article approvals support traceability and compliance for U.S. projects.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment offers a compact portfolio of drop designs that fit indoor risers and long aerial runs. 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 simple routing in hallways and MDUs.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs use a messenger element to handle tension. Choose FRP (dielectric) for non-conductive runs or steel messenger when bonding/grounding and higher tensile strength are required.
Core Layouts and Strength Members
We offer both dielectric and metallic strength member configurations to meet safety/EMI requirements. Center loose tube and unitube flat types balance crush resistance and fiber ribbone 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 | Best use | Strength member | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting (aerial) | Overhead spans | FRP/Steel | PE |
| Central loose-tube | Higher-count builds | Dielectric FRP | LSZH or PE |
| Flat unitube | Low count, quick strip | FRP or steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation with sensor feedback at Shanghai Weiye OFC Equipment cut manual handling and increase throughput for drop patch preparation.
Our production line integrates automated machines that cut/strip drop cords to increase output 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.
Auto Cut & Strip Capabilities
The equipment strips LSZH and PVC jackets and trims FRP or steel strength members to precise reserved lengths. Cylinder-driven actuators provide quick, repeatable motion and minimize 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 out-of-control conditions occur.
| Feature | Capability | Benefit |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Pneumatic cylinders | Fast/reliable motion |
| Material handling | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic feeders keep the line clean.
- PCPs capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets without sacrificing accuracy.
CLX-BPO2 auto-stripping machine capabilities in our line
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, reducing 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 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 jacket and reserved strength lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable jacket strip length from 17.5 to 35.0 mm. Reserved strength member stubs are set between 7.0 and 11.0 mm to fit common termination hardware.
Cutting FRP/Steel Members
The machine cleanly cuts FRP and steel wire strength elements while protecting neighboring fibers. Customized cutters are offered for non-standard cross-sections to maintain precision.
- Automatic waste ejection and sensor start cut idle time.
- Compact size (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg weight simplify cell integration.
- Pneumatic cylinders and PLC/photoelectric control boost reliability and lower maintenance interruptions.
| Spec | Value | Why it matters |
|---|---|---|
| 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 | 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 helps our production lines meet volume goals without compromising quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures every order to fit your network requirements and simplify field rollout. We combine focused options with predictable schedules so your teams receive ready-to-install products.
Choose 1 to 4 cores with single-mode or multimode fiber. Options include OS1, OS2, and OM2–OM4 plus G.652D and G.657 variants to align with optics and connector plans.
We Pantone-match sheath colors for fast field ID and consistent asset tags.
Jacket materials, print legends, and branding
Select LSZH, PVC, or PE jackets to suit route and safety requirements. Custom legends/logos aid inventory/warranty tracking.
Put-Ups, Packaging, and Structures
Standard put-ups are 1/2/4 km with tailored reels and packaging to suit storage and handling. Choose bow-type flat or self-supporting designs and steel wire or FRP strength members to fit span and isolation requirements.
| Choice | Typical | Advantage |
|---|---|---|
| Length | 1 / 2 / 4 km | Simpler staging and reels |
| Jacket | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Structure | Flat bow / Self-supporting | Flexible routing/span |
As a supplier, Shanghai Weiye schedules runs to your plan and delivers documentation that lists final specifications for easy on-site QA.
Quality, Test, and Docs
Shanghai Weiye OFC Equipment builds checkpoints into production so every item ships with recorded acceptance data.
High-temperature, salt spray, and vibration laboratory testing
Our lab conducts elevated-temperature exposure, salt spray 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 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 claims are easy to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- Line checks and final inspection prevent field failures and cut warranty events.
- QA packages include spec confirmation and formatted data for rapid review.
- Continuous test trends inform preventive maintenance and raise long-term reliability.
| Test | Purpose | Outcome |
|---|---|---|
| High-temperature | Material stability | Validated heat endurance |
| Salt-fog | Corrosion robustness | Qualified for outdoor use |
| Vibration | Resistance to vibration | Improved field reliability |
Pricing and cost drivers for FTTH drop cable
Budgeting for a drop run starts with fiber and jacket choices and is refined 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 design structure.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber grade, jacket material, and the structural type chosen for deployment.
Self-supporting designs 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 put-ups and larger volumes lower unit cost. Small quantities 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 align price quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Factor | Price impact | Recommendation |
|---|---|---|
| Optical grade | High impact | Balance spec vs. budget |
| Jacket type | Medium impact | Compare LSZH vs. PE for total cost |
| Length/Volume | Large | 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 schedules reduce downtime and help control cost 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 track your milestones and to keep deliveries on time.
The service team issues production updates and tracking so installation teams can plan arrivals. For compressed schedules, we hold contingency capacity to accelerate critical-path orders.
Why MOQ Matters
The MOQ is 1 km. This reflects setup needs such as wire and jacket die adjustments that use startup material and generate scrap.
We review your put-ups and staging to select reels to reduce waste/handling. Batch releases can balance inventory with more frequent small-site deliveries.
Installation Scenarios & Readiness
On-site conditions dictate whether a self-supporting aerial, ducted pull, or direct-buried run is the right choice for a project.
Aerial, duct, and direct-buried deployment considerations
For aerial runs, Shanghai Weiye OFC Equipment advises self-supporting designs with correct strength members to manage sag/tension for long-term stability.
Duct installations perform best with low-friction sheaths and crush-resistant builds so pulling does not damage fibers. 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 favor LSZH jackets to meet smoke/flame codes. Flat drop profiles strip clean and present controlled strength stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding requirements, lightning risk, and hardware fit. Standardized line prep shortens install time and reduces scrap.
| Scenario | Key feature | Field 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 jacket, tight bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That leads to fewer callbacks, faster activations, and reliable 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 pilot builds. We provide doc templates and clear install 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 with free replacement if any quality problems are confirmed.
- Schedule coordination for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed specs consistently.
| Support area | What we do | Benefit |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Reduced field issues |
| QA/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 provide custom FTTH drops 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 prep assets, cuts variability and shortens turnaround. Our equipment and machines standardize strip/stub lengths so installers see 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 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.