FTTH Drop Cable Production: Step-by-Step Manufacturing Process
Surprising fact: in excess of seventy percent of new U.S. broadband builds now depend on fiber networks that demand precise manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment runs complete FTTH cable production line manufacturing, from choosing brand fibers like Fujikura or Corning® SMF-28e to complete test reports that deliver 100% QA.
Our drop cable designs suit aerial, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and PE jacket options and core counts from 1–4 cores. We offer single-mode OS1/OS2 and OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone sheath colors, and logo printing.
Automated machines and precision equipment keep line speed steady and keep repeatability high. Typical lead times are 4–5 days for orders under 100 km and 7–10 days for < 500 km, with an MOQ of 1 km and warranty for free replacement on quality issues.
Read on to see how materials, testing, and support work together to reduce lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment provides full manufacturing with lab validation for United States projects.
- Multiple jacket choices and optical grades fit different install environments.
- Automated production lines provide stable quality and reliable optical performance.
- Quick lead times, low minimums, and brand fiber options support reliable procurement planning.
- Comprehensive test reports and after-sales warranty back product reliability and compliance documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment provides customized drop cables with full test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment combines specialized equipment with stringent material control. We offer customized service and products for residential and MDU rollouts. Every order includes full QA coverage and full test reports.
Our lab conducts high-temperature, salt-fog, and vibration testing to validate durability. Jacket options include LSZH, PVC, and PE. Designs offer bow-type flat and figure-8/self-supporting styles and support brand fibers such as Fujikura® and Corning® SMF-28e.
- Controlled production lines and in-process checks for auditable shipments.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixtures and calibration reduce variability so every cable meets operator standards.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are built around network requirements, combining brand fiber choices with disciplined test flows.
Optical fiber selection and brand options
We align fiber secondary coating line to minimum bend radius, attenuation, 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.
Strength Member Options
Strength members use dielectric FRP or metallic steel wire. FRP is preferred where non-conductivity is necessary. Steel wire adds tensile strength for long-span aerial runs and grounding needs.
Jacket Options and Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility, and PE for UV/moisture resistance outdoors. Tight process control of extruder temperature and capstan speed stabilizes line speed and critical dimensions.
| Member | Dielectric FRP | Metallic Steel |
|---|---|---|
| Use case | Non-conductive runs | High-tension aerial runs |
| Advantage | Lightweight, inert | High strength |
| Installation note | Easier terminations | Bonding/grounding required |
In-Process and Final Testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests verify loss and reflectance. Each order includes a full test report and lab results from high heat, salt fog, and vibration tests 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. Material lot records and first-article approvals provide traceability and compliance for U.S. programs.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment provides 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 keeps bend loss low for easy routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs use a support messenger to carry tensile loads. Choose dielectric FRP for electrical isolation or steel wire when bonding/grounding and extra tensile strength are required.
Layouts & Strength Members
We offer dielectric and metallic strength member configurations to match safety and EMI rules. Center loose tube and flat unitube types balance crush resistance and Fiber draw tower for quick termination.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor UV and moisture resilience. Each family is qualified for mechanical and optical quality before shipment.
| Type | Application | Strength member | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting (aerial) | Aerial spans | Steel wire or FRP | Polyethylene |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH or PE |
| Flat unitube | Low-count, easy strip | FRP/Steel | LSZH/PE |
Equipment Ensuring Quality and Throughput
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment reduce manual handling and boost throughput for patch cord prep.
Our production line integrates automated machines that cut/strip drop cords to increase output and cut labor variability.
The CLX-BPO2 automated stripper runs under PLC and photoelectric control. One cycle is ~1.5 s, giving ~20 terminals per minute in production.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise reserved lengths. Cylinder-driven actuators deliver fast, 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 out-of-control conditions occur.
| Feature | Spec | Benefit |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Pneumatic cylinders | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Process control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Automated waste ejection and ergonomic feeders keep the line clean.
- PCPs document calibration and key parameters.
- Integrated assets and trained operators support FTTH volume targets without compromising 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 uses the CLX-BPO2 to raise output and standardize terminal quality. The unit cycles in ~1.5 seconds, producing around 20 preps per minute in production.
PLC/photoelectric control enable precise detection and repeatable motion. That control keeps strip and stub lengths within tight tolerances.
Line Speed
Typical operation speed is 1.5s per cycle. This converts 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 to 35.0 mm. Reserved strength member stubs are adjustable from 7.0–11.0 mm to match common termination hardware.
Cutting FRP/Steel Members
The machine cleanly cuts FRP and steel wire strength elements while protecting adjacent fibers. Custom tooling are available for non-standard cross-sections to maintain precision.
- Automatic waste ejection and sensor-triggered start cut idle time.
- Small footprint (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 | Rating | Why it matters |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5–35.0 mm | Compatible with common connectors |
| Reserved stub (B) | 7.0 to 11.0 mm | Supports termination strength |
| Power & size | 110–220V, 50W; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes terminal prep so field teams get drop parts install-ready. The CLX-BPO2 supports our lines in meeting volume targets without compromising 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 receive ready-to-install products.
Choose 1 to 4 cores with SM or MM fiber. Options include OS1, OS2, and OM2–OM4 plus G.652D/G.657 variants to match your optics and connector plans.
We match sheath colors to Pantone codes for quick field identification and consistent asset tagging.
Jackets, Legends & Branding
Select LSZH/PVC/PE jackets based on route and safety rules. Custom print legends and 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 flat bow-type or self-supporting and steel wire or FRP strength members to fit span and isolation requirements.
| Choice | Common choice | Advantage |
|---|---|---|
| Reel length | 1, 2, or 4 km | Simpler staging and reels |
| Sheath | LSZH, PE, PVC | Indoor/Outdoor fit |
| Structure | Bow-type / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and provides docs that detail final specs for straightforward QA on site.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line so every item ships with recorded acceptance data.
High-temperature, salt spray, and vibration laboratory testing
Our lab runs high-temperature exposure, salt spray corrosion, and vibration tests to qualify materials/assemblies. These tests recreate field stresses for indoor/outdoor applications.
Per-Reel 100% Reports
Every fiber optic cable ships with 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 & Compliance
Lot/batch records tie test data to reels and 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 quick review.
- Ongoing trend analysis drive preventive maintenance and improve long-term reliability.
| Trial | Why | Outcome |
|---|---|---|
| Heat exposure | Material stability | Validated heat endurance |
| Salt spray | Corrosion robustness | Outdoor suitability |
| Vibration | Resistance to vibration | Reduced field failures |
FTTH Drop Cable Pricing & Cost Drivers
Budget planning for a drop begins with fiber/jacket selection 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 material, length, and structural design.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, jacket material, and the chosen structure for deployment.
Self-supporting structures and steel members raise material and labor input. Custom colors, logos, and print legends add setup time and impact pricing on small runs.
How Volume & Options Affect Cost
Longer put-ups and larger volumes lower unit cost. Small quantities often carry setup fees and higher unit prices.
- Line changeovers and custom tooling extend lead time and add to 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 | Guidance |
|---|---|---|
| Fiber grade | Large | Balance spec vs. budget |
| Jacket type | Medium | Compare LSZH vs. PE for total cost |
| Order length / volume | Large | Consolidate runs to cut unit cost |
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 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 tight schedules, we hold contingency capacity to accelerate critical-path orders.
Minimum order quantity and why it matters
The MOQ is one kilometer. This reflects setup needs such as wire/die adjustments that use startup material and generate scrap.
We review your put-ups and staging to select reels to reduce waste/handling. Staggered batches can balance inventory with more frequent small-site deliveries.
Installation Scenarios & Readiness
Site conditions dictate whether a self-supporting span, ducted 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 recommends self-supporting designs with correct strength members to control sag and tension for long-term reliability.
Duct installations perform best with low-friction sheaths and crush-resistant constructs so pulling avoids fiber damage. PE jackets are common for underground and buried paths where moisture resistance is needed.
Direct-buried designs need correct burial depth per local codes and moisture-resistant jackets to protect the fiber core long-term.
Indoor Riser/Plenum & ONT
Indoor riser and plenum routes prefer LSZH to meet smoke/flame codes. Flat drop cable forms strip clean and present controlled strength stubs for quick ONT termination.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware compatibility. Standardized prep from the production line reduces install time and minimizes scrap.
| Deployment | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct-buried | PE with moisture barrier | Follow depth/warning tape codes |
| Interior | LSZH jacket, tight bend support | Maintain bend radius at wall penetrations |
Our approach delivers a consistent installation across indoor/outdoor transitions. That reduces callbacks, speeds activations, and reliable field performance for your system.
Support from Spec to Service
Our team coordinates tests, line schedules, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements capture through approved drawings and pre-production builds. We deliver documentation templates and clear install notes so field crews share a unified 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 includes free replacement for confirmed quality issues.
- Schedule coordination for expedites and urgent changes.
- Configuration control so shipped items match agreed specs consistently.
| Area | What we do | Benefit |
|---|---|---|
| Tech/Eng | Specs + pilots | Reduced field issues |
| QA/Testing | Lab trials & 100% test reports | Full traceability |
| Service | Rapid replacement & root-cause | 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 ships with a 100% test report and documented trials to support field acceptance in the United States.
A robust production line, including CLX-BPO2-enabled prep machines, cuts variability and speeds turnaround. Our equipment set standardize strip and stub lengths so installers see consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance performance and cost to extend service life. Dedicated support covers scheduling/logistics/after-sales so your deployment stays on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every fiber optic and optic cable shipment with lab validation and responsive service.