FTTH Drop Cable Production: Manufacturing Process Explained
Quick fact: more than seventy percent of new U.S. broadband builds now depend on fiber networks that need high-precision manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment runs complete Fiber cable sheathing line manufacturing, from sourcing brand fibers like Fujikura® or Corning SMF-28e to complete test reports that ensure 100% quality assurance.
Our drop cable designs suit aerial, ducted, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and polyethylene (PE) jacket options and core counts from 1 to 4 cores. We supply single-mode OS1/OS2 and OM2–OM4 grades plus G.652D and G.657 variants, Pantone sheath colors, and custom 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 understand how materials plus testing and support work together to reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment provides complete production and laboratory testing for United States projects.
- Multiple jacket choices and optical grades fit varied installation environments.
- Automated production lines provide consistent quality and stable optical performance.
- Fast lead times, low minimums, and brand fiber options keep procurement predictable.
- Comprehensive test reports and warranty back product reliability and compliance documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment delivers customized drop cables with complete test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment pairs specialized equipment with tight material control. We provide customized service and products for residential and MDU rollouts. Every order comes with full QA coverage and full test reports.
Our lab performs high-temperature, salt-fog, and vibration tests 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 production checks for shipments with audit trails.
- Technical support for requirements, pilots, and scaling.
- Modern fixturing and calibration minimize variation so every cable meets carrier standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, combining brand fiber choices with rigorous test routines.
Optical fiber selection and brand options
We match fiber ribbon line to minimum bend radius, attenuation, 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 satisfy sourcing standards.
Strength Member Options
Strength members employ dielectric FRP or metallic steel wire. FRP is ideal where non-conductive runs are required. Steel wire adds tensile strength for long-span aerial runs and grounding needs.
Jacket Options and Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility and ease of handling, and PE for UV/moisture resistance outdoors. Tight process control of temperature and capstan ratios keeps line speed stable and critical dimensions.
| Component | Dielectric FRP | Steel wire |
|---|---|---|
| Primary use | Electrical isolation | Aerial spans, high tensile |
| Advantage | Light, non-corrosive | High strength |
| Installer note | Simple terminations | Requires grounding |
Testing & Verification
Inline geometry and concentricity checks operate in-line. Final optical tests verify attenuation and reflectance. Each order ships with a full test report and lab results from high-temperature, salt fog, and vibration trials to confirm handling for drop terminations and field use.
Typical lead times are under 100 km in 4–5 days and under 500 km in 7–10 days. Lot records and first-article approvals provide 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 stable optical performance.
The flat bow-type drop keeps a small footprint for risers and conduit. It reduces bend loss for simple routing in MDU corridors and hallways.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs use a messenger element to carry tensile loads. Choose FRP (dielectric) for non-conductive runs or steel messenger when bonding/grounding and extra tensile strength are required.
Strength member and core layouts
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 Fiber coloring machine for fast terminations.
Indoor/outdoor jackets
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor durability. Each series is validated for mechanical and optical quality before shipment.
| Type | Application | Strength element | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers and MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting | Overhead spans | FRP/Steel | PE |
| Central loose-tube | Higher fiber counts | FRP | LSZH or PE |
| Unitube flat | Low count, quick strip | FRP or steel | LSZH or PE |
Production line equipment that ensures quality and speed
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 raise throughput and reduce operator variability.
The CLX-BPO2 auto-stripping machine uses PLC + 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/steel members to precise stub lengths. Cylinder-driven actuators deliver fast, repeatable motion and low downtime.
PLC & Photoelectric for Precision
PLC logic + photoelectric sensors deliver precise positioning and closed-loop control. Inline checks feed control charts so operators can adjust drifts before defects grow.
| Feature | Capability | Result |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | High throughput |
| Drive | Pneumatic cylinders | High speed and reliability |
| Material handling | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic feeders maintain clean workcells.
- Process control plans 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 brings industrial-grade stripping and trimming to our line, reducing 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, yielding about 20 terminal preparations 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.
Throughput & Cycle Time
Typical operation speed is ~1.5 seconds per cycle. This translates to steady throughput under continuous line conditions.
Jacket Strip & Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets 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.
FRP & Steel Member Handling
The machine cleanly cuts FRP and steel wire strength elements while protecting neighboring fibers. Customized cutters are offered for non-standard cross-sections to preserve precision.
- Auto-eject scrap and sensor-triggered start cut idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg weight ease integration into workcells.
- Cylinder-driven motion and PLC/photoelectric control boost reliability and lower maintenance interruptions.
| Specification | Value | Why it matters |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| 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 prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 helps our production lines meet volume goals without sacrificing quality.
Tailored Specifications for Your Network
Shanghai Weiye OFC Equipment configures every order to meet your network requirements and simplify field rollout. 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 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 tags.
Jacket materials, print legends, and branding
Select LSZH, PVC, or PE jackets based on route and safety rules. Custom print legends and logos aid inventory/warranty tracking.
Length options, packaging, and special structures
Standard reel lengths are 1 km, 2 km, and 4 km with custom reels and packaging to fit storage/handling. Choose flat bow-type or self-supporting and steel wire or FRP strength members to meet span and isolation needs.
| Option | Common choice | Advantage |
|---|---|---|
| Length | 1, 2, or 4 km | Less staging, easier reels |
| Sheath | 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 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 has recorded acceptance data at ship.
Environmental and Mechanical Tests
Our lab runs high-temperature exposure, salt spray corrosion, and vibration tests to qualify materials and assemblies. These tests recreate field stresses for indoor/outdoor applications.
100% test reports for every cable
Every fiber optic cable ships with 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.
Traceability & Compliance
Batch records link tests to reels/serials so audits and warranty claims are simple to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- Line checks and final inspection reduce field failures and cut warranty events.
- QA packages include specifications confirmation and formatted test data for quick review.
- Continuous test trends drive preventive maintenance and raise long-term reliability.
| Trial | Why | Outcome |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt spray | Corrosion resistance | Qualified for outdoor use |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
FTTH Drop Cable Pricing & Cost Drivers
Budget planning for a drop starts with fiber and jacket choices and is shaped 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 design structure.
Material choices, fiber grade, jacket type, and structure
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 impact pricing on small runs.
Order length, volume, and customization impact on price
Longer put-ups and larger volumes lower unit cost. Short runs often include setup charges and higher per-unit charges.
- Line changeovers and custom tooling increase lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets across phases.
| Factor | Effect on price | Guidance |
|---|---|---|
| Optical grade | Large | Balance spec vs. budget |
| Jacket type | Medium | Evaluate LSZH vs PE |
| Length/Volume | High impact | Consolidate where possible |
Logistics for the U.S.
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align crews and sites. Predictable windows reduce downtime and help control cost 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 can plan arrivals. For compressed schedules, we hold contingency capacity to pull in critical-path orders.
Minimum order quantity and why it matters
The MOQ is 1 km. 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 holding with frequent, smaller deliveries to job sites.
Where and How to Deploy
Site conditions dictate whether a self-supporting aerial, duct pull, or direct burial is the right choice for a project.
Deployment Considerations
For aerial runs, Shanghai Weiye OFC Equipment recommends self-supporting designs with appropriate members to control sag and tension for long-term reliability.
Duct installations work best with low-friction sheaths and crush-resistant builds so pulling avoids fiber damage. 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-resistant jackets to protect the optic core over time.
Indoor Riser/Plenum & ONT
Indoor riser/plenum routes prefer LSZH to meet flame and smoke rules. Flat drop cable forms strip cleanly and present controlled 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 reduces install time and minimizes scrap.
| Deployment | Key feature | Installer note |
|---|---|---|
| Overhead | 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 local depth and warning tape rules |
| Indoor | LSZH jacket, tight bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor/outdoor transitions. That reduces callbacks, speeds activations, and stable 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 provides engineering support from early requirements capture through approved drawings and pilot builds. We provide doc templates and clear installation 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 updates and technical guidance.
- Warranty includes free replacement for confirmed quality issues.
- Coordination of line schedules for expedites and urgent changes.
- Config control so shipped items match agreed specs consistently.
| Area | What we do | Benefit |
|---|---|---|
| Tech/Eng | Specs + pilots | Fewer field issues |
| QA/Testing | Lab trials & 100% test reports | Traceable quality |
| Service | Rapid replacement & root-cause | Minimized downtime |
Conclusion
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 ships with a 100% test report and documented trials to support field acceptance in the United States.
A hardened production line, including CLX-BPO2 prep assets, cuts variability and speeds turnaround. Our equipment and machines standardize strip/stub lengths so installers get consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance performance and cost to extend service life. Dedicated customer support covers scheduling/logistics/after-sales so your deployment stays on plan.
Contact Shanghai Weiye OFC Equipment to align specs, timeline, and volume. We stand behind every shipment with lab validation and responsive support.