FTTH Drop Cable Production: Step-by-Step Manufacturing Process
Surprising fact: in excess of 70% of new broadband deployments in the U.S. now rely on fiber networks that require high-precision manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment manages complete fiber secondary coating line manufacturing, from selecting brand fibers like Fujikura® or Corning® SMF-28e to comprehensive test documentation that guarantee full quality assurance.
Our FTTH drop designs are built for overhead, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), PVC, and PE jacket options and core counts from 1–4 cores. We supply OS1/OS2 and multimode OM2–OM4 grades plus ITU-T G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automation and precision equipment keep line speed steady and keep repeatability high. Typical lead times run four to five days for orders under 100 km and 7–10 days under 500 km, with an MOQ of 1 km and warranty covering free replacement for confirmed quality issues.
Keep reading to learn how materials, testing, and support combine to lower lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment delivers full manufacturing with lab validation for United States projects.
- A range of jacket options and fiber grades support different install environments.
- Automated production lines provide consistent quality and reliable optical performance.
- Fast lead times, low minimums, and recognized brand fibers support reliable procurement planning.
- Comprehensive test reports and warranty back product reliability and documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment provides customized drop cables with full test documentation.
As a specialized maker and supplier, Shanghai Weiye OFC Equipment pairs purpose-built equipment with stringent material control. We offer customized service and products for residential and MDU rollouts. Every order comes with full QA coverage and full test reports.
Our lab performs high heat, salt spray, 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 auditable shipments.
- Technical support for requirements, pilots, and scaling.
- Modern fixtures and calibration minimize variation so every cable matches operator specs.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are built around network requirements, combining brand fiber choices with rigorous test routines.
Fiber Selection & Brand Options
We match fiber ribbon line to minimum bend radius, attenuation, 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 available to satisfy sourcing standards.
Strength Member Options
Strength members use dielectric FRP or metallic steel wire. FRP is ideal where non-conductive runs are required. Steel wire provides tensile strength for long-span aerial runs and bonding/grounding needs.
Extrusion & Process Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility, and PE for UV/moisture resistance outdoors. Closed-loop control of temperature and capstan ratios stabilizes line speed and critical dimensions.
| Member | Dielectric FRP | Metallic Steel |
|---|---|---|
| Primary use | Non-conductive runs | High-tension aerial runs |
| Key benefit | Light, non-corrosive | High strength |
| Installation note | Simple terminations | Bonding/grounding required |
In-Process and Final Testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests confirm loss and return loss. Each order ships with a 100% 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. Material 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 compact portfolio of drop designs that suit both 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 keeps a small footprint for risers/ducts. It keeps bend loss low for easy routing in MDU corridors and hallways.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs include a messenger element to handle tension. Choose dielectric FRP for electrical isolation or steel messenger when bonding/grounding and extra tensile strength are required.
Layouts & Strength Members
We provide dielectric and metallic strength member configurations to meet safety/EMI requirements. 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 flame-retardant, low-smoke indoor use and PE for outdoor UV and moisture resilience. Each family is qualified for mechanical and optical quality before shipment.
| Design | Application | Strength member | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | Dielectric FRP | Low-smoke zero-halogen |
| Self-supporting | Overhead spans | Steel wire or FRP | Polyethylene |
| Central loose-tube | Higher fiber counts | FRP | LSZH or PE |
| Flat unitube | Low count, quick strip | FRP or steel | LSZH or PE |
Production Assets for Speed and Quality
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and increase throughput for patch cord prep.
Our production line integrates automated machines that cut and strip drop patch cords to increase output and cut labor variability.
The CLX-BPO2 automated stripper uses PLC + photoelectric control. One cycle is ~1.5 s, giving real-world speeds near 20 terminal operations per minute.
Auto Cut & Strip Capabilities
The equipment strips LSZH and PVC jackets and trims FRP or steel strength members to precise stub lengths. Pneumatic cylinder actuators provide quick, repeatable motion and low downtime.
Closed-Loop Control for Repeatability
PLC logic and photoelectric sensors deliver precise positioning and closed-loop control. Inline checks feed control charts so operators can adjust drifts before defects grow.
| Item | Capability | Result |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Material handling | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Control | PLC + photoelectric + inline checks | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic feeders keep the line clean.
- PCPs capture calibration intervals and critical parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without sacrificing 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 uses 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 enable precise detection and repeatable actuation. That control keeps strip and stub lengths within tight tolerances.
Line Speed
Typical operation speed is ~1.5 seconds per cycle. This translates to steady throughput under normal production conditions.
Jacket Strip & Stub Lengths
The CLX-BPO2 strips LSZH and PVC jackets with an adjustable strip length from 17.5 to 35.0 mm. Reserved stubs are adjustable from 7.0–11.0 mm to match common termination hardware.
FRP & Steel Member Handling
The machine cuts FRP/steel strength elements cleanly while protecting adjacent fibers. Customized cutters are offered for non-standard cross-sections to preserve precision.
- Automatic waste ejection and sensor start reduce idle time.
- Small footprint (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass simplify cell integration.
- Cylinder-driven motion and closed-loop control boost reliability and reduce maintenance downtime.
| Specification | Value | Benefit |
|---|---|---|
| Cycle time | ≈1.5 s (~20/min) | Supports high-volume runs |
| Strip lengths (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 helps our production lines meet volume goals without sacrificing quality.
Customized specifications to fit 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 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 put-ups are 1/2/4 km with custom reels and packaging to suit storage and handling. Choose bow-type flat or self-supporting designs and steel wire or FRP strength members to fit span and isolation requirements.
| Option | Common choice | Advantage |
|---|---|---|
| Reel length | 1, 2, or 4 km | Less staging, easier reels |
| Sheath | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Design | Flat bow / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and delivers documentation that lists final specifications for easy on-site QA.
Quality assurance, testing, and 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 conducts elevated-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials and assemblies. These tests recreate field stresses for indoor and outdoor use.
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 QC gates stop nonconforming items before they leave the factory.
Audit Trail and Compliance
Lot/batch records link tests to reels/serials so audits and claims are easy to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection prevent field failures and cut warranty events.
- QA packages include specifications confirmation and formatted data for quick review.
- Continuous test trends inform preventive maintenance and raise long-term reliability.
| Trial | Purpose | Result |
|---|---|---|
| Heat exposure | Thermal stability | Validated heat endurance |
| Salt-fog | Corrosion robustness | 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 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 design structure.
Materials, Grade, Jacket & Structure
The primary cost drivers are fiber grade, sheath material, and the structural type chosen for deployment.
Self-supporting structures and steel strength elements increase material/labor. Custom colors, logos, and print legends add setup time and impact pricing on small runs.
Order length, volume, and customization impact on price
Longer reels and higher volume orders lower unit cost. Short runs often carry setup fees and higher unit prices.
- Line changeovers and custom tooling increase 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 | Price impact | Recommendation |
|---|---|---|
| Optical grade | Large | Balance spec vs. budget |
| Jacket type | Medium | Evaluate LSZH vs PE |
| Order 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 staffing and sites. Predictable schedules reduce downtime and help control cost when a rollout is underway.
Typical production windows and capacity planning
Typical production windows run 4–5 days for orders under 100 km and 7–10 days for < 500 km. We schedule line capacity to match your rollout milestones and to keep deliveries on time.
The service team issues production updates and tracking so installation teams know when reels arrive. For tight schedules, we hold contingency capacity to pull in critical-path orders.
MOQ and Rationale
The MOQ is one kilometer. This reflects line setup such as wire/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 holding with frequent, smaller deliveries to job sites.
Installation Scenarios & Readiness
On-site conditions dictate whether a self-supporting aerial, ducted pull, or direct burial 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 correct strength members to manage sag/tension for long-term stability.
Duct installations work best with low-friction sheaths and crush-resistant constructs so pulling does not damage fibers. PE jackets are typical for underground and buried paths where moisture resistance is needed.
Direct-buried designs require proper depth control per local codes and moisture barriers to protect the optic core over time.
Indoor riser/plenum distribution and ONT termination
Indoor riser/plenum routes favor LSZH jackets to meet flame and smoke rules. Flat drop cable forms 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 risk, and hardware fit. Standardized prep from the production line shortens install time and minimizes scrap.
| Deployment | Key design | Field note |
|---|---|---|
| Aerial | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow depth/warning tape codes |
| Interior | LSZH with tight-bend support | Maintain bend radius at penetrations |
Our approach delivers a consistent installation across indoor outdoor transitions. That leads to fewer callbacks, faster activations, and stable field performance for your system.
Support from Spec to 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 pilot builds. We deliver documentation 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.
- Coordination of line schedules for expedites and urgent changes.
- Configuration control so shipped items match agreed specs consistently.
| Support area | What we do | Benefit |
|---|---|---|
| Tech/Eng | Specs + pilots | Fewer field issues |
| Testing | Lab trials & 100% test reports | Traceable quality |
| After-sales | Rapid replacement & root-cause | Minimized downtime |
Final Thoughts
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
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 robust production line, including CLX-BPO2-enabled prep machines, reduces variability and speeds turnaround. Our equipment set standardize strip and stub lengths so installers see consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance performance and cost to extend service life. Dedicated support covers scheduling/logistics/after-sales so your deployment stays on plan.
Contact Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with laboratory validation and responsive support.