FTTH Drop Cable Production: Manufacturing Process Explained
Quick fact: in excess of 70% of U.S. broadband rollouts now depend on fiber networks that demand high-precision manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment handles full-cycle fiber secondary coating line manufacturing, from sourcing brand fibers like Fujikura or Corning SMF-28e to comprehensive test documentation that guarantee full quality assurance.
Our drop cable designs are built for aerial, ducted, and direct burial installation, with LSZH, PVC, and polyethylene (PE) jacket options and configurations from 1–4 cores. We offer OS1/OS2 and multimode OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automated machines and precision equipment stabilize line speed and keep repeatability high. Typical lead times run 4–5 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 our materials, tests, and support work together to reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment delivers full manufacturing with lab validation for United States projects.
- Multiple jacket choices and optical grades cover different install environments.
- Automated production lines provide consistent quality and reliable optical performance.
- Quick lead times, low minimums, and brand fiber options keep procurement predictable.
- Comprehensive test reports and warranty support product reliability and compliance documentation needs.
Specialized FTTH Manufacturing by Shanghai Weiye OFC Equipment
When project timelines and performance matter, Shanghai Weiye OFC Equipment provides customized drop cables with full test documentation.
As a dedicated manufacturer, Shanghai Weiye OFC Equipment pairs specialized equipment with tight material control. We offer custom builds and services for residential and MDU rollouts. Every order comes with 100% quality assurance and complete test reports.
Our lab conducts high heat, salt-fog, and vibration tests to validate durability. Jacket options include LSZH, PVC, and PE. Designs offer bow-type flat and figure-8/self-supporting styles and support brand fibers such as Fujikura® and Corning SMF-28e.
- Documented line control and in-process checks for shipments with audit trails.
- Engineering support for specs, trials, and ramp to volume.
- Modern fixturing and calibration reduce variability so every cable matches operator specs.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are built around network requirements, pairing brand fiber choices with strict test routines.
Fiber Selection & Brand Options
We match Fiber coloring machine to bend radius, loss, and install environment. 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 meet procurement standards.
Strength member integration
Strength members employ FRP (dielectric) or galvanized steel wire. FRP is ideal where non-conductivity is necessary. Steel wire provides tensile strength for long-span aerial runs and bonding/grounding needs.
Jacket extrusion and process control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility, and PE for outdoor UV and moisture resistance. Closed-loop control of temperature and capstan ratios keeps line speed stable and dimensional tolerances.
| Component | Dielectric FRP | Metallic Steel |
|---|---|---|
| Primary use | Non-conductive runs | High-tension aerial runs |
| Advantage | 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 confirm loss and return loss. Each order ships with a 100% test report and lab results from high-temperature, salt-spray, 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. Material lot records and FAI approvals support traceability and compliance for U.S. projects.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment offers a focused 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 stable optical performance.
The flat bow-type drop keeps a small footprint for risers/ducts. It reduces bend loss for easy 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 dielectric FRP for electrical isolation or steel wire when bonding/grounding and higher tensile strength are required.
Strength member and core layouts
We offer 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 secondary coating line for fast terminations.
Indoor vs Outdoor Jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each family is qualified for mechanical/optical performance before shipment.
| Design | Application | Strength element | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting | Overhead spans | FRP/Steel | PE |
| Center loose tube | Higher fiber counts | FRP | LSZH/PE |
| Unitube flat | Low count, quick strip | FRP/Steel | LSZH or PE |
Production Assets for Speed and Quality
Automation with sensor feedback at Shanghai Weiye OFC Equipment reduce manual handling and boost 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 runs under PLC and photoelectric control. One cycle is about 1.5 seconds, giving ~20 terminals per minute in production.
Auto Cut & Strip Capabilities
The equipment strips LSZH and PVC jackets and trims FRP/steel members to precise stub lengths. Pneumatic cylinder actuators deliver fast, repeatable motion and low downtime.
PLC & Photoelectric for Precision
PLC logic and photoelectric sensors give exact positioning and feedback control. Inline checks feed control charts so operators can adjust drifts before defects grow.
| Feature | Capability | Result |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Drive | Cylinder-based | Fast/reliable motion |
| Materials | LSZH & PVC; FRP & steel | Clean, accurate preps |
| Process control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Auto scrap ejection and ergonomic feeders keep the line clean.
- PCPs capture calibration intervals and critical parameters.
- Integrated assets and trained operators help meet FTTH volume goals without compromising accuracy.
CLX-BPO2 Capabilities on Our Line
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, reducing cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment deploys the CLX-BPO2 to increase throughput and standardize terminal quality. The unit cycles in ~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 ~1.5 seconds per cycle. This enables 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 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 neighboring fibers. Customized cutters are available 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 weight simplify cell integration.
- Cylinder-driven motion and closed-loop control improve line reliability and lower maintenance interruptions.
| Spec | Value | Benefit |
|---|---|---|
| Cycle | ≈1.5 s (~20/min) | Supports high-volume runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Compatible with common connectors |
| Stub (B) | 7.0 to 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 terminal 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 every order 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 and G.657 variants to align with optics and connector plans.
We Pantone-match sheath colors for fast field ID and consistent asset tagging.
Jacket materials, print legends, and branding
Select LSZH, PVC, or PE jackets to suit route and safety requirements. Custom print legends and logos support inventory and warranty tracking.
Length options, packaging, and special structures
Standard put-ups are 1/2/4 km with tailored 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.
| Option | Common choice | Advantage |
|---|---|---|
| Length | 1 / 2 / 4 km | Simpler staging and reels |
| Sheath | LSZH / PE / PVC | Indoor/Outdoor fit |
| Design | Flat bow / Self-supporting | Flexible routing/span |
As a supplier, Shanghai Weiye schedules runs to your plan and provides docs that lists final specifications for straightforward QA on site.
Quality assurance, testing, and 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 spray corrosion, and vibration tests to qualify materials/assemblies. These tests simulate field stresses for indoor and outdoor use.
100% test reports for every cable
Every fiber optic cable ships with a 100% test report that logs attenuation, return loss, and geometry where applicable. Final inspection gates prevent nonconforming shipments before they leave the factory.
Traceability & Compliance
Lot/batch records link tests to reels/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.
- QA packages include specifications confirmation and formatted test data for quick review.
- Ongoing trend analysis inform preventive maintenance and raise long-term reliability.
| Trial | Purpose | Outcome |
|---|---|---|
| Heat exposure | Thermal stability | Validated heat endurance |
| Salt-fog | Corrosion resistance | Outdoor suitability |
| Vibration | Mechanical robustness | Improved field reliability |
Pricing and cost drivers for FTTH drop cable
Budgeting for a drop run 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, jacket material, and the structural type chosen for deployment.
Self-supporting designs and steel strength elements raise material and labor input. Custom sheath colors/logos/legends add setup and impact pricing on small runs.
How Volume & Options Affect Cost
Longer reels and higher volume orders lower unit cost. Small quantities often carry setup fees and higher per-unit charges.
- Changeovers and special cutters extend 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 across phases.
| Driver | Effect on price | Recommendation |
|---|---|---|
| Optical grade | High impact | Right-size spec to budget |
| Sheath material | Medium impact | Evaluate LSZH vs PE |
| Order 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 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 schedule line capacity to match your rollout milestones and to maintain on-time delivery.
The service team issues production updates and tracking so installation teams know when reels arrive. For compressed schedules, we reserve contingency capacity to pull in critical-path orders.
Minimum order quantity and why it matters
The MOQ is 1 km. 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
On-site conditions dictate whether a self-supporting aerial, ducted pull, or direct burial is the right choice for a project.
Aerial, duct, and direct-buried deployment considerations
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 perform best with low-friction jackets and crush-resistant builds so pulling avoids fiber damage. PE jackets are typical for underground and buried paths where moisture resistance matters.
Direct-buried designs need correct burial depth per local codes and moisture barriers to protect the fiber core long-term.
Indoor Distribution and ONT
Indoor riser and 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 needs, lightning exposure, and hardware compatibility. Standardized line prep reduces install time and reduces scrap.
| Deployment | Key design | Installer note |
|---|---|---|
| Aerial | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct-buried | PE jacket, moisture barrier | Follow local depth and warning tape rules |
| 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, speeds activations, and stable field performance for your system.
Comprehensive Support & After-Sales
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 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 help 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 urgent changes or acceleration requests.
- Config control so shipped items match agreed specs consistently.
| Support area | What we do | Outcome |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Fewer field issues |
| QA/Testing | Lab trials & 100% test reports | Full traceability |
| Service | Rapid replacement & root-cause | Minimized 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 includes a 100% test report and documented lab trials to support U.S. field acceptance.
A hardened production line, including CLX-BPO2-enabled prep machines, reduces variability and speeds turnaround. Our equipment set standardize strip and stub lengths so installers get consistent results at turn-up.
From fiber selection to jacket, printing, and packaging, we balance design 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 specs, timeline, and volume. We stand behind every fiber optic and optic cable shipment with laboratory validation and responsive service.