FTTH Drop Cable Production: Step-by-Step Manufacturing Process
Quick fact: in excess of seventy percent of new U.S. broadband builds now use fiber networks that require high-precision manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment runs end-to-end fiber secondary coating line manufacturing, from selecting brand fibers like Fujikura® or Corning® SMF-28e to complete test reports that deliver 100% QA.
Our drop designs fit aerial, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and PE jacket options and configurations from 1 to 4 cores. We offer OS1/OS2 and OM2–OM4 grades plus G.652D and G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automated machines and high-precision equipment stabilize line speed and keep repeatability high. Typical lead times run 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.
Continue to see how materials plus testing and support combine to lower lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment delivers end-to-end manufacturing and lab testing for United States projects.
- A range of jacket options and fiber grades cover varied installation environments.
- Automated lines and machines ensure stable quality and stable optical performance.
- Quick lead times, low MOQ, and recognized brand fibers help plan procurement reliably.
- Comprehensive test reports and after-sales warranty support product reliability and documentation needs.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment provides customized drop cables with complete test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment combines purpose-built equipment with tight material control. We offer customized service and products for single-family and MDU rollouts. Every order includes 100% quality assurance and full test reports.
Our lab conducts high-temperature, salt-fog, and vibration tests to validate durability. Jacket options include LSZH, PVC, and PE. Designs cover bow-type flat and figure-8/self-supporting styles and support brand fibers such as Fujikura® and Corning SMF-28e.
- Documented line control and production checks for auditable shipments.
- Technical support for specs, trials, and ramp to volume.
- Modern fixturing and calibration minimize variation 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.
Optical fiber selection and brand options
We select fiber secondary coating line to minimum 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 Options
Strength members employ FRP (dielectric) or metallic steel wire. FRP is ideal where non-conductive runs are required. Steel wire provides tensile strength for longer aerial spans and bonding/grounding needs.
Jacket extrusion and process control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility and ease of handling, and PE for UV/moisture resistance outdoors. Closed-loop control of temperature and capstan ratios stabilizes line speed and critical dimensions.
| Member | FRP | Metallic Steel |
|---|---|---|
| Primary use | Electrical isolation | Aerial spans, high tensile |
| Advantage | Light, non-corrosive | High strength |
| Installer note | Simple terminations | Bonding/grounding required |
Testing & Verification
Inline geometry/concentricity checks operate in-line. Final optical tests verify loss and return loss. Each order includes a 100% test report and lab results from high heat, salt fog, 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 first-article approvals support traceability and compliance for U.S. projects.
FTTH Drop Designs We Build
Shanghai Weiye OFC Equipment offers a focused portfolio of FTTH drop designs that suit both tight indoor routes and exposed aerial spans. Each option combines tested materials with field-termination geometry and stable optical performance.
The bow-type flat drop cable keeps a small 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 include a support messenger to carry tensile loads. Choose dielectric FRP for electrical isolation or steel messenger when bonding 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 unitube flat types balance crush resistance and compact fiber unit for fast terminations.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each family is validated for mechanical/optical performance before shipment.
| Type | Best use | Strength member | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | Dielectric FRP | LSZH |
| Self-supporting | Aerial spans | Steel wire or FRP | Polyethylene |
| Central loose-tube | Higher fiber counts | FRP | LSZH or PE |
| Unitube flat | Low count, quick strip | FRP or steel | LSZH/PE |
Production Assets for Speed and Quality
Automation with sensor 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 raise throughput 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 cutting and stripping for drop cable patch cords
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise reserved lengths. Pneumatic cylinder actuators provide quick, repeatable motion and minimize downtime.
Closed-Loop Control for Repeatability
PLC logic + photoelectric sensors give exact positioning and closed-loop control. Inline checks update SPC charts so operators can correct trends before defects grow.
| Feature | Spec | Benefit |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Actuation | Pneumatic cylinders | High speed and reliability |
| Material handling | LSZH/PVC; FRP/steel | Clean, accurate preps |
| Process control | PLC/photoelectric with in-line SPC | Stable quality, reduced rework |
- Automated waste ejection and ergonomic loading keep the line clean.
- Process control plans capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without sacrificing accuracy.
CLX-BPO2 Capabilities on Our Line
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 increase throughput 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.
Throughput & Cycle Time
Typical operation speed is 1.5s per cycle. This enables steady throughput under continuous line conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable jacket strip length from 17.5 to 35.0 mm. Reserved stubs are adjustable from 7.0–11.0 mm to fit common termination hardware.
Cutting FRP/Steel Members
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Customized cutters are offered for nonstandard sizes to maintain precision.
- Auto-eject scrap and sensor start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass ease integration into workcells.
- Cylinder-driven motion and PLC/photoelectric control improve line reliability and reduce maintenance downtime.
| Specification | Rating | Benefit |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Reserved stub (B) | 7.0 to 11.0 mm | Meets strength and termination needs |
| Power & size | 110–220V, 50W; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes 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 combine focused options with predictable schedules so your teams get install-ready reels.
Choose 1–4 core designs with single-mode or multimode 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 fast field ID and consistent asset tagging.
Jacket materials, print legends, and branding
Select LSZH/PVC/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 km, 2 km, and 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 meet span and isolation needs.
| Choice | Typical | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and reels |
| Sheath | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Structure | Bow-type / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and delivers documentation that lists final specifications for straightforward QA on site.
Quality, Test, and Docs
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 conducts high-temperature exposure, salt spray corrosion, and vibration tests to qualify materials and assemblies. These tests simulate field stresses for indoor/outdoor applications.
Per-Reel 100% Reports
Every fiber optic cable ships with 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 and compliance
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.
- Continuous test trends inform preventive maintenance and raise long-term reliability.
| Trial | Why | Result |
|---|---|---|
| Heat exposure | Thermal stability | Validated heat endurance |
| Salt spray | Corrosion resistance | Qualified for outdoor use |
| Vibration | Mechanical robustness | Improved field reliability |
Cost Drivers and Pricing
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 chemistry (LSZH, PVC, PE), reel length, and design structure.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber grade, jacket material, and the chosen structure for deployment.
Self-supporting structures and steel members increase material/labor. Custom colors, logos, and print legends add setup and influence price for short runs.
Length/Volume/Customization Impact
Longer reels and higher volume orders reduce 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 and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets over phases.
| Factor | Effect on price | Recommendation |
|---|---|---|
| Optical grade | Large | Right-size spec to budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Length/Volume | High impact | Consolidate where possible |
Logistics for the U.S.
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews and sites. Predictable schedules reduce downtime and control costs when a rollout is underway.
Production Windows & Capacity
Typical production windows are 4–5 days for < 100 km and 7–10 days for orders under 500 km. We schedule line capacity to track your milestones and to maintain on-time delivery.
The service team issues production updates and tracking so installation teams can plan arrivals. For tight schedules, we hold contingency capacity to pull in critical-path orders.
Why MOQ Matters
The MOQ is one kilometer. This reflects setup needs 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 more frequent small-site deliveries.
Installation readiness and application scenarios
On-site conditions dictate whether a self-supporting aerial, ducted pull, or direct-buried run is the best fit for a project.
Deployment Considerations
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with correct strength members to manage sag/tension for long-term stability.
Duct installations perform best with low-friction jackets 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 need correct burial depth per local codes and moisture barriers to protect the optic core over time.
Indoor riser/plenum distribution and ONT termination
Indoor riser and plenum routes favor LSZH jackets to meet flame and smoke rules. 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 fit. Standardized prep from the production line reduces install time and minimizes scrap.
| Scenario | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Duct | Low-friction jacket, crush resistance | Use pull tape + lubricant |
| Direct-buried | PE with moisture barrier | Follow local depth and warning tape rules |
| Indoor | LSZH with tight-bend support | Maintain bend radius at penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That reduces callbacks, faster activations, and stable field performance for your system.
End-to-end support and after-sales service
Our team coordinates tests, line schedules, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements through approved drawings and pilot builds. We deliver documentation templates and clear install notes so field crews work from the same plan.
After-sales service includes fast response, RCA, and corrective action. All products ship with full reports and traceability to support QA acceptance.
- Round-the-clock availability for status and technical support.
- Warranty includes free replacement for confirmed quality issues.
- Coordination of line schedules for expedites and urgent changes.
- Configuration control so shipped items match agreed specs consistently.
| Support area | Scope | Outcome |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| Testing | Lab + 100% reports | Full traceability |
| Service | Rapid replacement & root-cause | Lower downtime |
Conclusion
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 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 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 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.