FTTH Drop Cable Production: Step-by-Step Manufacturing Process
Surprising fact: more than 70% of new broadband deployments in the U.S. now depend on fiber networks that need high-precision manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment handles end-to-end fiber secondary coating line manufacturing, from choosing brand fibers like Fujikura or Corning SMF-28e to final test reports that ensure 100% quality assurance.
Our FTTH drop designs fit overhead, underground, and direct burial installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and PE jacket options and core counts from 1 to 4 cores. We offer OS1/OS2 and multimode OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone sheath colors, and logo printing.
Automated machines and precision equipment stabilize line speed and maximize repeatability. Typical lead times run four to five days for orders under 100 km and seven to ten days under 500 km, with an min. order of 1 km and free-replacement warranty for quality problems.
Continue to understand how materials plus testing and support help reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment provides end-to-end manufacturing and lab testing for United States projects.
- A range of jacket options and optical grades fit indoor/outdoor environments.
- Automated production lines provide stable quality and reliable optical performance.
- Fast lead times, low MOQ, and recognized brand fibers keep procurement predictable.
- 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 delivers tailored drop solutions with full test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment combines purpose-built equipment with tight material control. We offer custom builds and services for residential and MDU rollouts. Every order comes with 100% quality assurance and complete test reports.
Our lab conducts high-temperature, salt-fog, and vibration testing to verify durability. Jacket options cover LSZH, PVC, and PE. Designs cover bow-type flat 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 shipments with audit trails.
- Engineering support for specification reviews, trials, and volume ramp.
- 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 rigorous test routines.
Selecting Optical Fiber and Brands
We match fiber secondary coating line to minimum bend radius, loss, and install environment. Options include OS1, OS2, 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 use 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.
Jacket extrusion and process control
Jacket options include LSZH for flame/smoke 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 | FRP | Metallic Steel |
|---|---|---|
| Primary use | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Lightweight, inert | High strength |
| Installer note | Simple terminations | Bonding/grounding required |
Testing & Verification
Inline geometry/concentricity checks operate in-line. Final optical tests confirm loss and return loss. Each order includes a full test report and lab results from high heat, salt fog, and vibration trials to qualify field handling and drop terminations.
Typical lead times are under 100 km in 4–5 days and 7–10 days for < 500 km. Lot records and first-article approvals provide traceability and compliance for U.S. programs.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment provides a focused portfolio of FTTH drop designs that cover 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 minimizes footprint for risers and conduit. It reduces bend loss for simple routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs include a support messenger to handle tension. Choose dielectric FRP for electrical isolation or steel wire when bonding and extra tensile strength are required.
Layouts & Strength Members
We offer both dielectric and metallic strength member configurations to match safety and EMI rules. Central loose-tube and unitube flat types balance crush resistance and Fiber draw tower for quick termination.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor UV and moisture resilience. Each family is validated for mechanical and optical quality before shipment.
| Type | Application | Strength member | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting | Overhead spans | FRP/Steel | Polyethylene |
| Center loose tube | Higher-count builds | FRP | LSZH or PE |
| Unitube flat | Low count, quick strip | FRP/Steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
Automation and sensor-driven feedback at Shanghai Weiye OFC Equipment reduce manual handling and increase throughput for drop patch preparation.
Our production line uses 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 about 1.5 seconds, giving real-world speeds near 20 terminal operations per minute.
Automated Cut/Strip for Drop Cords
The equipment strips LSZH/PVC jackets and trims FRP or steel strength members to precise reserved lengths. Pneumatic cylinder actuators provide quick, repeatable motion and minimize downtime.
PLC/photoelectric control for precision and repeatability
PLC logic and photoelectric sensors give exact positioning and feedback control. Inline checks update SPC charts so operators can correct trends before defects grow.
| Item | Capability | Benefit |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Materials | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic loading maintain clean workcells.
- PCPs document calibration and key parameters.
- Integrated assets and trained operators 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 raise output and standardize prep quality. The unit cycles in ~1.5 seconds, producing around 20 preps per minute in production.
PLC and photoelectric control enable precise detection and repeatable motion. That control keeps strip and stub lengths within tight tolerances.
Cycle time and throughput
Typical operation speed is 1.5s per cycle. This enables steady throughput under normal production conditions.
Jacket Strip & Stub 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 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. Customized cutters are available for nonstandard sizes to maintain precision.
- Auto-eject scrap and sensor-triggered start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg weight simplify cell integration.
- Pneumatic cylinders and PLC/photoelectric control improve line reliability and reduce maintenance downtime.
| Spec | Rating | Why it matters |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | Supports high-volume runs |
| Strip lengths (A) | 17.5–35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0–11.0 mm | Meets strength and termination needs |
| Power & size | 50W @ 110–220V; 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 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 pair concise options with predictable manufacturing windows so your teams get install-ready reels.
Choose 1–4 core designs with single-mode or multimode fiber. Options include OS1/OS2 plus OM2–OM4 plus G.652D/G.657 variants to align with optics and connector plans.
We match sheath colors to Pantone codes for quick field identification and consistent asset tagging.
Branding and Print Options
Select LSZH, PVC, or PE jackets based on route and safety rules. Custom print legends and logos support inventory and 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 meet span and isolation needs.
| Option | Common choice | Benefit |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Less staging, easier reels |
| Jacket | LSZH / PE / PVC | Indoor/Outdoor fit |
| Design | Flat bow / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye aligns runs to your schedule 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 conducts high-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials and assemblies. These tests simulate field stresses for indoor/outdoor applications.
100% test reports for every cable
Every fiber optic cable includes a 100% test report that records loss, return loss, and key geometry where applicable. Final QC gates prevent nonconforming shipments before they leave the factory.
Audit Trail and 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 accelerate approvals and receiving inspection.
- Line checks and final inspection reduce field failures and lower warranty events.
- QA packages include specifications confirmation and formatted test data for quick review.
- Continuous test trends drive preventive maintenance and improve long-term reliability.
| Trial | Purpose | Result |
|---|---|---|
| High-temperature | Thermal stability | Validated heat endurance |
| Salt spray | Corrosion robustness | Outdoor suitability |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
Pricing and cost drivers for FTTH drop cable
Budgeting for a drop run begins with fiber/jacket selection and is refined by volume and customization.
Typical prices range broadly—from about $30–$1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket chemistry (LSZH, PVC, PE), reel length, and structural design.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, jacket material, and the structural type chosen 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.
How Volume & Options Affect Cost
Longer put-ups and larger volumes reduce unit cost. Short runs 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 match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets across phases.
| Factor | Price impact | Guidance |
|---|---|---|
| Optical grade | High impact | Balance spec vs. budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| 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 < 500 km. We plan 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 compressed schedules, we reserve contingency capacity to pull in critical-path orders.
MOQ and Rationale
The MOQ is one kilometer. This reflects line setup such as wire and jacket die adjustments that consume start-up material and scrap.
We review your length and staging plans to select reels to reduce waste/handling. Batch releases can balance inventory with more frequent small-site deliveries.
Installation Scenarios & Readiness
Site conditions determine whether a self-supporting span, ducted pull, or direct-buried run 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 correct strength members to manage sag/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 typical 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 Distribution and ONT
Indoor riser/plenum routes favor LSZH jackets to meet flame and smoke rules. Flat drop profiles strip clean and present controlled stubs for quick ONT termination.
We guide the choice of steel or FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware compatibility. Standardized prep from the production line shortens install time and minimizes scrap.
| Deployment | Key feature | Installer note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Underground duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow local depth and warning tape rules |
| Indoor | LSZH with tight-bend support | Maintain bend radius at 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 offers engineering support from early requirements through approved drawings and pilot builds. We provide doc templates and clear installation notes so field crews share a unified 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 updates and technical guidance.
- Warranty with free replacement if any quality problems are confirmed.
- Schedule coordination for expedites and urgent changes.
- Configuration control so shipped items match agreed requirements every time.
| Area | Scope | Outcome |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| Testing | Lab + 100% reports | Full traceability |
| After-sales | Fast replace + RCA | Minimized downtime |
Final Thoughts
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
We deliver customized FTTH drop solutions that pair material choices with validated manufacturing and lab testing. Every reel includes a 100% test report and documented trials to support field acceptance in the United States.
A hardened production line, including CLX-BPO2-enabled prep machines, reduces variability and speeds 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 design and cost to extend service life. Dedicated customer support covers scheduling/logistics/after-sales so your deployment remains on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every shipment with laboratory validation and responsive support.