FTTH Drop Cable Production: Step-by-Step Manufacturing Process
Surprising fact: over seventy percent of new broadband deployments in the U.S. now rely on fiber networks that demand tight manufacturing control to achieve required performance.
Shanghai Weiye OFC Equipment runs complete FTTH cable production line manufacturing, from choosing brand fibers like Fujikura® or Corning® SMF-28e to final test reports that guarantee full quality assurance.
Our drop cable designs fit aerial, underground, and direct-buried installation, with LSZH, polyvinyl chloride (PVC), and polyethylene (PE) jacket options and arrangements from 1 to 4 cores. We provide OS1/OS2 and OM2–OM4 grades plus ITU-T 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 min. order of 1 km and warranty covering free replacement for confirmed quality issues.
Read on to see how our materials, tests, and support help reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment offers full manufacturing with lab validation for United States projects.
- A range of jacket options and optical grades fit indoor/outdoor environments.
- Automated production lines provide stable quality and stable optical performance.
- Quick lead times, low MOQ, and recognized brand fibers support reliable procurement planning.
- Comprehensive test 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 provides customized drop cables with full test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment combines purpose-built equipment with tight material control. We provide customized service and products for residential/MDU deployments. Every order comes with 100% quality assurance and full test reports.
Our lab performs high heat, salt spray, and vibration tests to validate durability. Jacket options cover LSZH, PVC, and PE. Designs cover flat bow-type and figure-8/self-supporting styles and use brand fibers such as Fujikura® and Corning® SMF-28e.
- Controlled production lines and in-process checks for auditable shipments.
- Technical support for requirements, pilots, and scaling.
- Modern fixturing and calibration reduce variability so every cable meets operator standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, pairing brand fiber choices with disciplined test flows.
Selecting Optical Fiber and Brands
We select fiber ribbon line 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 meet procurement standards.
Strength member integration
Strength members employ dielectric FRP or galvanized steel wire. FRP is preferred where non-conductivity is necessary. Steel wire adds tensile strength for long-span aerial runs 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 stabilizes line speed and dimensional tolerances.
| Component | FRP | Metallic Steel |
|---|---|---|
| Primary use | Electrical isolation | High-tension aerial runs |
| Advantage | Light, non-corrosive | Very high tensile strength |
| Installation note | Easier terminations | Bonding/grounding required |
Inline and final testing
Inline geometry and concentricity checks run during manufacturing. Final optical tests verify loss and return loss. Each order includes a full test report and lab results from high-temperature, salt fog, and vibration tests 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. 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 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 stable optical performance.
The flat bow-type drop minimizes footprint for risers and conduit. It reduces bend loss for simple 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 messenger when bonding/grounding and higher tensile strength are required.
Layouts & Strength Members
We provide both dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and unitube flat types balance crush resistance and Fiber draw tower for fast terminations.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor durability. Each series is qualified for mechanical and optical quality before shipment.
| Design | Application | Strength element | Sheath |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | FRP (dielectric) | LSZH |
| Self-supporting | Overhead spans | FRP/Steel | Polyethylene |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Unitube flat | Low count, quick 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 drop patch preparation.
Our production line integrates automated machines that cut/strip drop cords to increase output and cut labor variability.
The CLX-BPO2 automated stripper uses PLC + photoelectric control. One cycle is about 1.5 seconds, giving ~20 terminals per minute in production.
Automated Cut/Strip for Drop Cords
The equipment strips LSZH and PVC jackets and trims FRP/steel members to precise stub lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and low downtime.
PLC & Photoelectric for Precision
PLC logic and photoelectric sensors give exact positioning and closed-loop control. Inline checks update SPC charts so operators can correct trends before defects grow.
| Feature | Capability | Result |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Actuation | Pneumatic cylinders | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic loading maintain clean workcells.
- PCPs capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets without sacrificing accuracy.
CLX-BPO2 Capabilities on Our Line
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, reducing cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output and standardize prep 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 helps keep strip lengths and reserved strength stubs within tight tolerances.
Line Speed
Typical operation speed is ~1.5 seconds per cycle. This converts to steady throughput under continuous line conditions.
Jacket Strip & Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable strip length from 17.5–35.0 mm. Reserved strength member 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. Customized cutters are available for non-standard cross-sections to maintain precision.
- Auto-eject scrap and sensor start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight simplify cell integration.
- Cylinder-driven motion and closed-loop control boost reliability and lower maintenance interruptions.
| Specification | Rating | Why it matters |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | High throughput for production runs |
| Strip lengths (A) | 17.5–35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0 to 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 receive drop parts ready for quick installation. The CLX-BPO2 helps our production lines meet volume goals without sacrificing 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 plus OM2–OM4 plus G.652D and G.657 variants to match your optics and connector plans.
We Pantone-match sheath colors for fast field ID and consistent asset tagging.
Branding and Print Options
Select LSZH, PVC, or PE jackets to suit route and safety requirements. Custom legends/logos aid inventory/warranty tracking.
Length options, packaging, and special structures
Standard reel lengths are 1/2/4 km with tailored 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.
| 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 delivers documentation that detail final specs 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.
Lab Testing: Heat, Salt Spray & Vibration
Our lab conducts elevated-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials and 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 logs attenuation, return loss, and geometry where applicable. Final QC gates stop nonconforming items before they leave the factory.
Traceability & Compliance
Lot/batch records tie test data to reels and serials so audits and warranty claims are simple to verify. Documentation follows common customer templates to speed approvals and inbound inspection.
- Line checks and final inspection reduce field failures and lower warranty events.
- Quality packages include spec confirmation and formatted data for quick review.
- Continuous test trends drive preventive maintenance and raise long-term reliability.
| Test | Why | Result |
|---|---|---|
| Heat exposure | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion resistance | Outdoor suitability |
| Mechanical vibration | Resistance to vibration | Improved field reliability |
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, jacket material, length, and design structure.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber grade, sheath 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 and influence price for short runs.
Order length, volume, and customization impact on price
Longer put-ups and larger volumes reduce unit cost. Small quantities often carry setup fees and higher unit prices.
- Line changeovers and custom tooling 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 |
|---|---|---|
| Fiber grade | Large | Balance spec vs. budget |
| Sheath material | Medium | Compare LSZH vs. PE for total cost |
| 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 windows cut downtime and help control cost when a rollout is underway.
Production Windows & Capacity
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 maintain on-time delivery.
The service team provides updates/tracking so installation teams know when reels arrive. For tight schedules, we reserve contingency capacity to pull in critical-path orders.
Why MOQ Matters
The MOQ is 1 km. 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
Site conditions determine whether a self-supporting aerial, ducted 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 advises self-supporting designs with correct strength members to control sag and tension for long-term stability.
Duct installations work 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 need correct burial depth 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 cleanly and present controlled strength stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding requirements, lightning exposure, and hardware compatibility. Standardized line prep shortens install time and minimizes scrap.
| Deployment | Key feature | Installer note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Underground duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow depth/warning tape codes |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That reduces callbacks, speeds activations, and reliable field performance for your system.
Comprehensive Support & After-Sales
Our team coordinates tests, line schedules, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements through approved drawings and pilot builds. We deliver documentation 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 includes free replacement for confirmed quality issues.
- Schedule coordination for urgent changes or acceleration requests.
- Config control so shipped items match agreed specs consistently.
| Support area | Scope | Outcome |
|---|---|---|
| Engineering | Spec review & pre-production builds | Fewer field issues |
| QA/Testing | Lab trials & 100% test reports | Traceable quality |
| After-sales | Rapid replacement & root-cause | Lower downtime |
Wrap-Up
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
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 U.S. field acceptance.
A robust production line, including CLX-BPO2-enabled prep machines, cuts variability and shortens turnaround. Our equipment and machines standardize strip and stub lengths so installers get consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance design and cost to maximize service life. Dedicated customer support guides scheduling, logistics, and after-sales care so your deployment remains on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with lab validation and responsive support.