FTTH Drop Cable Production: Manufacturing Process Explained
Surprising fact: over seventy percent of new U.S. broadband builds now rely on fiber networks that demand precise manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment handles complete Fiber cable sheathing line manufacturing, from choosing brand fibers like Fujikura® or Corning SMF-28e to complete test reports that ensure 100% quality assurance.
Our drop designs are built for overhead, ducted, and direct burial 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 multimode OM2–OM4 grades plus G.652D and G.657 variants, Pantone sheath colors, and logo printing.
Automated machines and high-precision equipment stabilize line speed and repeatability high. Typical lead times run 4–5 days for orders < 100 km and seven to ten days under 500 km, with an min. order of 1 km and warranty for free replacement on quality issues.
Keep reading to learn how materials, testing, and support help reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment provides complete production and laboratory testing for United States projects.
- Multiple jacket choices and fiber grades support different install environments.
- Automated production lines deliver stable quality and reliable optical performance.
- Quick lead times, low minimums, and recognized brand fibers support reliable procurement planning.
- Complete reports and warranty back product reliability and compliance documentation needs.
Expert 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 focused supplier and manufacturer, Shanghai Weiye OFC Equipment pairs specialized equipment with tight material control. We provide customized service and products for single-family and MDU rollouts. Every order includes 100% quality assurance and complete test reports.
Our lab performs high heat, salt spray, and vibration tests to validate durability. Jacket options cover LSZH, PVC, and PE. Designs offer flat bow-type and 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 specification reviews, trials, and volume ramp.
- Modern fixtures and calibration reduce variability so every cable meets operator standards.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, pairing brand fiber choices with rigorous test routines.
Fiber Selection & Brand Options
We align fiber ribbon line to minimum bend radius, attenuation, 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 available to satisfy sourcing 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 longer aerial spans and grounding needs.
Extrusion & Process Control
Jacket options include LSZH for indoor flame safety, PVC for flexibility, and PE for UV/moisture resistance outdoors. Closed-loop control of temperature and capstan ratios stabilizes line speed and dimensional tolerances.
| Member | FRP | Metallic Steel |
|---|---|---|
| Primary use | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Lightweight, inert | High strength |
| Installer note | Easier terminations | Bonding/grounding required |
Inline and final testing
Inline geometry and concentricity checks run during manufacturing. Final optical tests verify attenuation and return loss. Each order ships with a 100% 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. Lot records and FAI approvals provide traceability and compliance for U.S. projects.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment offers a focused portfolio of drop designs that cover tight indoor routes and exposed aerial spans. Each option combines tested materials with field-termination geometry and consistent 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.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs include a messenger element to carry tensile loads. Choose dielectric FRP for electrical isolation or steel messenger when bonding/grounding and extra tensile strength are required.
Layouts & Strength Members
We provide both dielectric and metallic strength member configurations to match safety and EMI rules. Central loose-tube and flat unitube types balance crush resistance and Fiber draw tower for fast terminations.
Jackets for Indoor/Outdoor
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.
| Design | Application | Strength member | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting (aerial) | Overhead spans | Steel wire or FRP | PE |
| Central loose-tube | Higher fiber counts | FRP | LSZH or PE |
| Flat unitube | Low count, quick strip | FRP/Steel | LSZH/PE |
Production line equipment that ensures quality and speed
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and boost 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 ~20 terminals per minute in production.
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 control for precision and repeatability
PLC logic and photoelectric sensors give exact positioning and feedback control. Inline checks update SPC charts so operators can adjust drifts before defects grow.
| Feature | Capability | Result |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Cylinder-based | Fast/reliable motion |
| Materials | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Automated waste ejection and ergonomic loading keep the line clean.
- Process control plans document calibration and key parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets without sacrificing accuracy.
CLX-BPO2 Capabilities on Our Line
The CLX-BPO2 provides industrial-grade strip/trim to our line, reducing cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment deploys the CLX-BPO2 to increase throughput and standardize prep quality. The unit runs at an approximate cycle time of 1.5 seconds, yielding about 20 terminal preparations 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 translates to steady throughput under normal production conditions.
Supported Strip and Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable jacket strip length from 17.5–35.0 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 offered for non-standard cross-sections to maintain precision.
- Automatic waste ejection and sensor-triggered 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 reduce maintenance downtime.
| Spec | Value | Benefit |
|---|---|---|
| Cycle time | ~1.5 s (~20/min) | Supports high-volume runs |
| Strip lengths (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Reserved stub (B) | 7.0–11.0 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 helps our production lines meet volume goals without compromising quality.
Custom Specs for Your FTTH System
Shanghai Weiye OFC Equipment configures each build to fit your network requirements and simplify field rollout. We combine focused options with predictable schedules so your teams get install-ready reels.
Choose 1–4 core designs with SM or MM fiber. Options include OS1/OS2 plus OM2–OM4 plus G.652D and G.657 variants to align with optics and connector plans.
We Pantone-match sheath colors for quick field identification and consistent asset tagging.
Jackets, Legends & Branding
Select LSZH/PVC/PE jackets based on route and safety rules. Custom legends/logos support inventory and warranty tracking.
Lengths, Packaging & Special Builds
Standard reel lengths are 1/2/4 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.
| Option | Common choice | Benefit |
|---|---|---|
| Length | 1, 2, or 4 km | Simpler staging and reels |
| Jacket | LSZH, PE, PVC | Indoor/Outdoor fit |
| Design | Bow-type / Self-supporting | Flexible routing/span |
As a supplier, Shanghai Weiye schedules runs to your plan and delivers documentation 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.
Lab Testing: Heat, Salt Spray & Vibration
Our lab conducts high-temperature exposure, salt spray corrosion, and mechanical vibration 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.
Audit Trail and Compliance
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.
- In-line checks plus final inspection reduce field failures and lower warranty events.
- QA packages include spec confirmation and formatted test data for rapid review.
- Ongoing trend analysis inform preventive maintenance and improve long-term reliability.
| Trial | Why | Outcome |
|---|---|---|
| Heat exposure | Thermal stability | Validated heat endurance |
| Salt-fog | Corrosion resistance | Outdoor suitability |
| Vibration | Resistance to vibration | Reduced field failures |
Cost Drivers and Pricing
Budget planning for a drop starts with fiber and jacket choices and is refined by volume and customization.
Typical prices vary widely—from about $30 to $1,000 per unit—based on fiber grade, jacket material, reel length, and structural design.
Primary Cost Inputs
The primary cost drivers are fiber optic grade, sheath material, and the chosen structure for deployment.
Self-supporting designs and steel members raise material and labor input. Custom sheath colors/logos/legends add setup time 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 include setup charges and higher per-unit charges.
- Changeovers and special cutters increase lead time and add 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.
| Driver | Price impact | Recommendation |
|---|---|---|
| Fiber grade | High impact | Balance spec vs. budget |
| Jacket type | Medium | Evaluate LSZH vs PE |
| Length/Volume | Large | Consolidate where possible |
U.S. Lead Times, MOQ & Delivery
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.
Production Windows & Capacity
Typical production windows are 4–5 days for < 100 km and 7–10 days for orders under 500 km. We plan capacity to track your milestones and to keep deliveries on time.
The service team issues production updates and tracking so installation teams can plan arrivals. For tight schedules, we hold contingency capacity to accelerate critical-path orders.
Minimum order quantity and why it matters
The MOQ is 1 km. This reflects line setup such as wire/die adjustments that use startup material and generate scrap.
We review your length and staging plans to choose reel sizes that cut waste and handling. Batch releases can balance inventory holding with more frequent small-site deliveries.
Where and How to Deploy
On-site conditions dictate 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 appropriate members to control sag and tension for long-term reliability.
Duct installations work best with low-friction jackets and crush-resistant constructs so pulling does not damage fibers. PE jackets are typical 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 fiber core long-term.
Indoor riser/plenum distribution and ONT termination
Indoor riser/plenum routes favor LSZH jackets to meet smoke/flame codes. Flat drop profiles strip cleanly and present controlled strength stubs for quick ONT termination.
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 reduces scrap.
| Scenario | Key design | Installer note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Underground duct | Low-friction jacket, crush resistance | Use pull tape and proper lubricant |
| Direct-buried | PE with moisture barrier | Follow local depth and warning tape rules |
| Indoor | LSZH with tight-bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor/outdoor transitions. That leads to fewer 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 offers engineering support from early requirements through approved drawings and pre-production builds. We provide doc templates and clear installation notes so field crews work from the same plan.
After-sales service covers rapid response, root-cause analysis, and corrective actions. All products ship with full reports and traceability to help 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 specs consistently.
| Area | What we do | Outcome |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| Testing | Lab trials & 100% test reports | Full traceability |
| Service | Fast replace + RCA | Lower downtime |
Wrap-Up
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 includes a 100% test report and documented trials to support U.S. field acceptance.
A robust production line, including CLX-BPO2 prep assets, cuts variability and speeds turnaround. Our equipment set standardize strip/stub lengths so installers get consistent results at turn-up.
From fiber selection through 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 fiber optic and optic cable shipment with lab validation and responsive service.