FTTH Drop Cable Production: Step-by-Step Manufacturing Process
Did you know: more than seventy percent of new broadband deployments in the U.S. now depend on fiber networks that need high-precision manufacturing to meet performance goals.
Shanghai Weiye OFC Equipment handles complete Fiber cable sheathing line manufacturing, from selecting brand fibers like Fujikura® or Corning SMF-28e to complete test reports that ensure 100% quality assurance.
Our drop designs fit aerial, underground, and direct-buried installation, with low-smoke zero-halogen (LSZH), polyvinyl chloride (PVC), and polyethylene (PE) jacket options and arrangements from 1–4 cores. We offer single-mode OS1/OS2 and multimode OM2–OM4 grades plus G.652D and G.657 variants, Pantone-matched sheath colors, and logo printing.
Automated machines and high-precision equipment stabilize line speed and maximize repeatability. Typical lead times are four to five days for orders under 100 km and seven to ten days under 500 km, with an MOQ of 1 km and warranty covering free replacement for confirmed quality issues.
Keep reading to understand how materials, testing, and support combine to lower lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment provides full manufacturing with lab validation for United States projects.
- Multiple jacket choices and fiber grades cover indoor/outdoor environments.
- Automated production lines ensure consistent quality and stable 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.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment delivers customized drop cables with full test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment pairs purpose-built equipment with tight material control. We provide custom builds and services for single-family and MDU rollouts. Every order includes full QA coverage and full test reports.
Our lab conducts high heat, salt-fog, and vibration tests to validate durability. Jacket options cover LSZH, PVC, and PE. Designs offer 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 fixtures and calibration minimize variation so every cable meets carrier standards.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are built around network requirements, pairing brand fiber choices with disciplined test flows.
Fiber Selection & Brand Options
We align fiber secondary coating 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 available to satisfy sourcing standards.
Integrating Strength Members
Strength members employ dielectric FRP or metallic steel wire. FRP is preferred where non-conductive runs are required. Steel wire provides tensile strength for longer aerial spans 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 stabilizes line speed and critical dimensions.
| Member | FRP | Metallic Steel |
|---|---|---|
| Primary use | Electrical isolation | Aerial spans, high tensile |
| Key benefit | Light, non-corrosive | High strength |
| Installation note | Simple terminations | Requires grounding |
Inline and final testing
Inline geometry and concentricity checks run during manufacturing. Final optical tests verify loss and reflectance. 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 4–5 days for < 100 km and under 500 km in 7–10 days. Lot records and first-article approvals support traceability and compliance for U.S. programs.
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 combines tested materials with field-termination geometry and stable optical performance.
The flat bow-type drop minimizes footprint for risers and conduit. It keeps bend loss low for simple routing in MDU corridors and hallways.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs use a support messenger to carry tensile loads. Choose dielectric FRP for non-conductive runs or steel wire when bonding and higher tensile strength are required.
Strength member and core layouts
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 coloring machine for quick termination.
Jackets for Indoor/Outdoor
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each family is qualified for mechanical and optical quality before shipment.
| Type | Application | Strength element | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting | Overhead spans | Steel wire or FRP | Polyethylene |
| Central loose-tube | Higher-count builds | Dielectric FRP | LSZH/PE |
| Unitube flat | Low-count, easy strip | FRP/Steel | LSZH/PE |
Production Assets for Speed and Quality
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 and strip drop patch cords to increase output and cut labor variability.
The CLX-BPO2 auto-stripping machine uses PLC + photoelectric control. One cycle is ~1.5 s, giving real-world speeds near 20 terminal operations per minute.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise stub lengths. Pneumatic cylinder actuators provide quick, 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 out-of-control conditions occur.
| Feature | Spec | Benefit |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | ~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 |
- Automated waste ejection and ergonomic loading maintain clean workcells.
- PCPs capture calibration intervals and critical parameters.
- Integrated assets and trained operators 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, cutting cycle time while maintaining consistent prep.
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/photoelectric control deliver exact 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 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 fit common termination hardware.
Handling FRP and steel wire strength members
The machine cuts FRP/steel strength elements cleanly while protecting neighboring fibers. Custom tooling are offered for non-standard cross-sections to preserve precision.
- Auto-eject scrap and sensor start cut idle time.
- Compact size (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass simplify cell integration.
- Cylinder-driven motion 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 | Easy integration into existing equipment |
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 sacrificing quality.
Tailored Specifications for Your Network
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 to 4 cores with SM or MM fiber. Options include OS1/OS2 plus OM2–OM4 along with 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.
Jackets, Legends & Branding
Select LSZH, PVC, or PE jackets to suit route and safety requirements. Custom print legends and logos support inventory and warranty tracking.
Lengths, Packaging & Special Builds
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 FRP or steel members to fit span and isolation requirements.
| Choice | Common choice | Advantage |
|---|---|---|
| Reel length | 1, 2, or 4 km | Simpler staging and reels |
| Sheath | LSZH / PE / PVC | Indoor/outdoor compatibility |
| Structure | Flat bow / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye schedules runs to your plan and provides docs that detail final specs for easy on-site QA.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment builds checkpoints into production so every item ships with recorded acceptance data.
High-temperature, salt spray, and vibration laboratory testing
Our lab runs high-temperature exposure, salt fog corrosion, and vibration tests to qualify materials/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 inspection gates prevent nonconforming shipments before they leave the factory.
Traceability & Compliance
Lot/batch records tie test data to reels and serials so audits and warranty claims are simple to verify. Documentation uses standard customer templates to accelerate approvals and receiving inspection.
- Line checks and final inspection prevent field failures and lower warranty events.
- Quality packages include spec confirmation and formatted data for quick review.
- Continuous test trends inform preventive maintenance and improve long-term reliability.
| Test | Why | Outcome |
|---|---|---|
| High-temperature | Material stability | Pass at target temperature |
| Salt spray | Corrosion robustness | Outdoor suitability |
| Vibration | Resistance to vibration | Improved field reliability |
Cost Drivers and Pricing
Budget planning for a drop begins with fiber/jacket selection and is shaped by volume and customization.
Typical prices vary widely—from about $30–$1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket material, length, and structural design.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber grade, jacket material, and the chosen structure for deployment.
Self-supporting structures and steel members raise material and labor input. Custom sheath colors/logos/legends add setup and impact pricing on small runs.
Order length, volume, and customization impact on price
Longer put-ups and larger volumes reduce unit cost. Short runs often include setup charges and higher unit prices.
- Changeovers and special cutters 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 over phases.
| Driver | Effect on price | Recommendation |
|---|---|---|
| Fiber grade | Large | Right-size spec to budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Order length / volume | High impact | Consolidate where possible |
Lead times, MOQ, and delivery for the United States
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align staffing and sites. Predictable schedules cut downtime and control costs 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 schedule line 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 pull in critical-path orders.
Why MOQ Matters
The MOQ is 1 km. This reflects setup needs such as wire and jacket die adjustments that consume start-up material and scrap.
We review your length and staging plans to choose reel sizes that cut waste and handling. Staggered batches can balance inventory with more frequent small-site deliveries.
Where and How to Deploy
On-site conditions determine whether a self-supporting aerial, duct pull, or direct burial is the best fit for a project.
Deployment Considerations
For aerial runs, Shanghai Weiye OFC Equipment advises self-supporting designs with correct strength members to control sag and tension for long-term stability.
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 is needed.
Direct-buried designs need correct burial depth per local codes and moisture-resistant jackets to protect the optic core over time.
Indoor Distribution and ONT
Indoor riser and plenum routes prefer LSZH to meet smoke/flame codes. Flat drop cable forms strip clean 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 compatibility. Standardized line prep reduces install time and reduces scrap.
| Scenario | Key design | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct burial | 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, speeds activations, and reliable 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 through approved drawings and pre-production builds. We deliver documentation 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 includes free replacement for confirmed quality issues.
- Schedule coordination for expedites and urgent changes.
- Configuration control so shipped items match agreed specs consistently.
| Support area | What we do | Outcome |
|---|---|---|
| Engineering | Spec review & pre-production builds | Reduced field issues |
| Testing | Lab trials & 100% test reports | Full traceability |
| Service | Rapid replacement & root-cause | Lower downtime |
Wrap-Up
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
We deliver customized FTTH drop solutions that combine materials with validated manufacturing and lab tests. Every reel ships with a 100% test report and documented trials to support U.S. field acceptance.
A robust production line, including CLX-BPO2-enabled prep machines, reduces variability and speeds turnaround. Our equipment set standardize strip/stub lengths so installers see consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance performance and cost to maximize service life. Dedicated support covers scheduling/logistics/after-sales so your deployment stays on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every shipment with lab validation and responsive service.