FTTH Drop Cable Production: Manufacturing Process Explained
Surprising fact: over seventy percent of new broadband deployments in the U.S. now use fiber networks that require precise manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment runs full-cycle fiber secondary coating line manufacturing, from choosing brand fibers like Fujikura® or Corning® SMF-28e to complete test reports that guarantee full quality assurance.
Our drop cable designs suit aerial, ducted, and direct burial installation, with LSZH, PVC, and PE jacket options and arrangements from 1–4 cores. We offer OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and logo printing.
Automation and high-precision equipment keep line speed steady and repeatability high. Typical lead times run four to five days for orders < 100 km and seven to ten days under 500 km, with an MOQ of 1 km and warranty for free replacement on quality issues.
Keep reading to see how materials, testing, and support help reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment offers full manufacturing with lab validation for United States projects.
- Multiple jacket choices and optical grades cover different install environments.
- Automated production lines deliver stable quality and stable optical performance.
- Quick lead times, low minimums, and brand fiber options keep procurement predictable.
- Complete reports and after-sales warranty support product reliability and compliance documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment delivers customized drop cables with complete test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment pairs specialized equipment with stringent material control. We provide customized service and products for single-family and MDU rollouts. Every order includes full QA coverage and full test reports.
Our lab runs high heat, salt-fog, and vibration tests to verify 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.
- Controlled production lines and in-process checks for shipments with audit trails.
- Technical support for specification reviews, trials, and volume ramp.
- Modern fixtures and calibration reduce variability 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 strict test routines.
Selecting Optical Fiber and Brands
We match fiber draw tower 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 integration
Strength members employ FRP (dielectric) or galvanized steel wire. FRP is preferred where non-conductivity is necessary. Steel wire adds tensile strength for long-span aerial runs and bonding/grounding needs.
Extrusion & 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 extruder temperature and capstan speed keeps line speed stable and dimensional tolerances.
| Member | FRP | Steel wire |
|---|---|---|
| Use case | Electrical isolation | High-tension aerial runs |
| Key benefit | Light, non-corrosive | High strength |
| Installation note | Easier terminations | Bonding/grounding required |
Testing & Verification
Inline geometry/concentricity checks operate in-line. Final optical tests confirm loss and return loss. Each order ships with a full test report and lab results from high heat, salt fog, and vibration tests to qualify field handling and drop terminations.
Typical lead times are 4–5 days for < 100 km and 7–10 days for < 500 km. 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 consistent optical performance.
The flat bow-type drop minimizes footprint for risers/ducts. It keeps bend loss low for simple routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs include a messenger element to handle tension. Choose FRP (dielectric) for non-conductive runs or steel messenger when bonding/grounding and extra tensile strength are required.
Layouts & Strength Members
We offer dielectric and metallic strength member configurations to meet safety/EMI requirements. Central loose-tube and flat unitube types balance crush resistance and fiber secondary coating line for quick termination.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for indoor flame/smoke compliance and PE for outdoor durability. Each family is qualified for mechanical and optical quality before shipment.
| Design | Best use | Strength element | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting (aerial) | Overhead spans | FRP/Steel | PE |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH or PE |
| Flat unitube | Low-count, easy strip | FRP/Steel | LSZH or PE |
Production Assets for Speed and Quality
Automation and sensor-driven 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 cut labor 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 and PVC jackets and trims FRP or steel strength members to precise reserved lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and minimize downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors deliver precise positioning and feedback control. Inline checks feed control charts so operators can correct trends before out-of-control conditions occur.
| Feature | Capability | Result |
|---|---|---|
| Machine | Auto-strip, ~1.5 s cycle | High throughput |
| Drive | Cylinder-based | High speed and reliability |
| Material handling | 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 keep the line clean.
- PCPs capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without compromising accuracy.
CLX-BPO2 Capabilities on Our Line
The CLX-BPO2 provides industrial-grade strip/trim to our line, cutting cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output 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 and photoelectric control enable precise detection and repeatable actuation. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Cycle time and throughput
Typical operation speed is 1.5s per cycle. This converts to steady throughput under continuous line conditions.
Jacket Strip & Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable strip length from 17.5–35.0 mm. Reserved stubs are set between 7.0 and 11.0 mm to fit common termination hardware.
Cutting FRP/Steel Members
The machine cleanly cuts FRP and steel wire strength elements while protecting adjacent fibers. Custom tooling 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), 50W at 110–220V, and 11 kg weight ease integration into workcells.
- Pneumatic cylinders and PLC/photoelectric control boost reliability and lower maintenance interruptions.
| Specification | Value | Why it matters |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0 to 11.0 mm | Supports termination strength |
| Power/Size | 110–220V, 50W; 40×18×18 cm | Easy integration into existing equipment |
Using this machine, Shanghai Weiye OFC Equipment standardizes prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 supports our lines in meeting volume targets without sacrificing quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures every order 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 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 quick field identification and consistent asset tagging.
Jackets, Legends & Branding
Select LSZH, PVC, or PE jackets to suit route and safety requirements. Custom legends/logos support inventory and 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 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 | Advantage |
|---|---|---|
| Reel length | 1, 2, or 4 km | Less staging, easier reels |
| Jacket | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Design | Bow-type / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and provides docs that detail final specs for easy on-site QA.
Quality assurance, testing, and documentation
Shanghai Weiye OFC Equipment builds checkpoints into production so every item has recorded acceptance data at ship.
High-temperature, salt spray, and vibration laboratory testing
Our lab conducts elevated-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials/assemblies. These tests recreate field stresses for indoor/outdoor applications.
100% test reports for every cable
Every fiber optic cable includes a 100% test report that logs attenuation, return loss, and geometry where applicable. Final QC gates prevent nonconforming shipments before they leave the factory.
Traceability & 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.
- Line checks and final inspection prevent field failures and lower warranty events.
- Quality packages include spec confirmation and formatted data for quick review.
- Ongoing trend analysis inform preventive maintenance and raise long-term reliability.
| Test | Purpose | Result |
|---|---|---|
| High-temperature | Material stability | Validated heat endurance |
| Salt-fog | Corrosion resistance | Qualified for outdoor use |
| Mechanical vibration | Resistance to vibration | Reduced field failures |
Cost Drivers and Pricing
Budget planning for a drop begins with fiber/jacket selection and is shaped by volume and customization.
Typical prices range broadly—from about $30–$1,000 per unit—based on fiber grade, jacket chemistry (LSZH, PVC, PE), reel length, and structural design.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber grade, sheath material, and the structural type chosen for deployment.
Self-supporting designs and steel strength elements increase material/labor. Custom colors, logos, and print legends add setup time and impact pricing on small runs.
Length/Volume/Customization Impact
Longer reels and higher volume orders lower unit cost. Small quantities often carry setup fees and higher per-unit charges.
- Changeovers and special cutters increase lead time and add to cost.
- Clear RFQs with schedule alignment let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets over phases.
| Factor | Price impact | Recommendation |
|---|---|---|
| Fiber grade | High impact | Right-size spec to budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Length/Volume | Large | Consolidate runs to cut unit cost |
Lead times, MOQ, and delivery for the United States
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews and sites. Predictable windows reduce downtime and help control cost when a rollout is underway.
Typical production windows and capacity planning
Typical production windows are 4–5 days for < 100 km and 7–10 days for < 500 km. We plan capacity to match your rollout milestones and to keep deliveries on time.
The service team provides updates/tracking so installation teams know when reels arrive. For tight schedules, we reserve contingency capacity to accelerate critical-path orders.
Why MOQ Matters
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 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 determine whether a self-supporting aerial, duct pull, or direct burial is the best fit for a project.
Aerial vs Duct vs Direct-Buried
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 perform best with low-friction jackets and crush-resistant constructs so pulling does not damage fibers. PE jackets are common for underground and buried paths where moisture resistance is needed.
Direct-buried designs require proper depth control per local codes and moisture-resistant jackets 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 cable forms strip cleanly and present controlled stubs for fast ONT terminations.
We guide the choice of steel or 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.
| Deployment | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting, steel or 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 jacket, tight bend support | Maintain bend radius at 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.
Comprehensive Support & After-Sales
Our team coordinates testing, scheduling, and installation guidance to avoid surprises in deployment.
Shanghai Weiye OFC Equipment offers engineering support from early requirements capture through approved drawings and pre-production builds. We provide doc templates and clear install 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 test 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.
- Config control so shipped items match agreed specs consistently.
| Support area | What we do | Benefit |
|---|---|---|
| Engineering | Spec review & pre-production builds | Fewer field issues |
| QA/Testing | Lab trials & 100% test reports | Full traceability |
| Service | 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 robust production line, including CLX-BPO2 prep assets, cuts variability and speeds turnaround. Our equipment set standardize strip and stub lengths so installers see 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 fiber optic and optic cable shipment with lab validation and responsive support.