FTTH Drop Cable Production: Step-by-Step Manufacturing Process
Quick fact: in excess of 70% of new broadband deployments in the U.S. now use fiber networks that require tight manufacturing control to achieve required performance.
Shanghai Weiye OFC Equipment manages complete Fiber cable sheathing line manufacturing, from selecting brand fibers like Fujikura® or Corning SMF-28e to complete test reports that deliver 100% QA.
Our drop designs are built for aerial, ducted, and direct burial installation, with low-smoke zero-halogen (LSZH), PVC, and polyethylene (PE) jacket options and arrangements from 1 to 4 cores. We offer OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and ITU-T G.657 variants, Pantone sheath colors, and logo printing.
Automated machines and high-precision equipment keep line speed steady and repeatability high. Typical lead times run four to five days for orders under 100 km and seven to ten days under 500 km, with an min. order of 1 km and warranty covering free replacement for confirmed quality issues.
Keep reading to understand how our materials, tests, and support combine to lower lifecycle cost and match the right product to your network system.
- Shanghai Weiye OFC Equipment offers complete production and laboratory testing for United States projects.
- A range of jacket options and fiber grades fit indoor/outdoor environments.
- Automated production lines ensure stable quality and reliable optical performance.
- Fast lead times, low MOQ, and brand fiber options keep procurement predictable.
- Comprehensive test reports and warranty back product reliability and compliance documentation needs.
FTTH Manufacturing Expertise 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 tight material control. We offer customized service and products for residential/MDU deployments. Every order includes full QA coverage and full test reports.
Our lab conducts high-temperature, salt spray, and vibration testing to verify durability. Jacket options include LSZH, PVC, and PE. Designs include 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 fully auditable shipments.
- Technical support for specs, trials, and ramp to volume.
- Modern fixturing and calibration reduce variability so every cable matches operator specs.
How We Produce FTTH Cable
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with strict test routines.
Fiber Selection & Brand Options
We match fiber draw tower to minimum bend radius, loss, 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 offered to meet procurement standards.
Strength Member Options
Strength members use dielectric FRP or galvanized steel wire. FRP is ideal where non-conductivity is necessary. Steel wire adds tensile strength for long-span aerial runs and bonding/grounding needs.
Jacket Options and Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility, and PE for outdoor UV and moisture resistance. Tight process control of extruder temperature and capstan speed stabilizes line speed and dimensional tolerances.
| Member | Dielectric FRP | Metallic Steel |
|---|---|---|
| Primary use | Non-conductive runs | Aerial spans, high tensile |
| Advantage | Lightweight, inert | Very high tensile strength |
| Installer note | Easier terminations | Bonding/grounding required |
Testing & Verification
Inline geometry and concentricity checks run during manufacturing. Final optical tests verify attenuation and reflectance. Each order ships with a full test report and lab results from high heat, salt-spray, and vibration trials to confirm handling for drop terminations and field use.
Typical lead times are 4–5 days for < 100 km and 7–10 days for < 500 km. Lot records and first-article approvals support traceability and compliance for U.S. programs.
Our FTTH Drop Cable Types and Structures
Shanghai Weiye OFC Equipment offers a compact portfolio of drop designs that suit both 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 reduces bend loss for simple routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs include a messenger element to handle tension. Choose FRP (dielectric) for electrical isolation or steel messenger when bonding/grounding and extra tensile strength are required.
Strength member and core layouts
We provide dielectric and metallic strength member configurations to match safety and EMI rules. Central loose-tube and flat unitube types balance crush resistance and compact fiber unit 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.
| Type | Application | Strength element | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | Dielectric FRP | LSZH |
| Self-supporting (aerial) | Overhead spans | FRP/Steel | PE |
| Center loose tube | Higher fiber counts | Dielectric FRP | LSZH/PE |
| Unitube flat | Low-count, easy strip | FRP or steel | LSZH or PE |
Equipment Ensuring Quality and Throughput
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 raise throughput and reduce operator variability.
The CLX-BPO2 auto-stripping machine uses PLC + photoelectric control. One cycle is ~1.5 s, giving ~20 terminals per minute in production.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise reserved lengths. Cylinder-driven actuators deliver fast, repeatable motion and minimize downtime.
PLC/photoelectric control for precision and repeatability
PLC logic + photoelectric sensors give exact positioning and closed-loop control. Inline checks update SPC charts so operators can correct trends before defects grow.
| Item | Spec | Result |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | ~20 terminals/minute throughput |
| Drive | Pneumatic cylinders | Fast/reliable motion |
| Material handling | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| Process control | PLC/photoelectric with in-line SPC | Consistent quality, lower rework |
- Auto scrap ejection and ergonomic feeders keep the line clean.
- Process control plans document calibration and key parameters.
- Combined machines, fixtures, and trained staff help meet FTTH volume goals without compromising accuracy.
CLX-BPO2 auto-stripping machine capabilities in our line
The CLX-BPO2 brings industrial-grade stripping and trimming to our line, cutting cycle time while keeping prep consistent.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to raise output 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 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 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.
Handling FRP and steel wire strength members
The machine cuts FRP/steel strength elements cleanly while protecting adjacent fibers. Customized cutters are available for nonstandard sizes to maintain precision.
- Automatic waste ejection and sensor start cut idle time.
- Compact size (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg weight simplify cell integration.
- Cylinder-driven motion and PLC/photoelectric control improve line reliability and reduce maintenance downtime.
| Specification | Rating | Benefit |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Fits common connector processes |
| Reserved stub (B) | 7.0–11.0 mm | Supports termination strength |
| 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 supports our lines in meeting volume targets without sacrificing quality.
Tailored Specifications for Your Network
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 receive ready-to-install products.
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 match your optics and connector plans.
We Pantone-match sheath colors for fast field ID and consistent asset tagging.
Branding and Print Options
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom legends/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 fit storage/handling. Choose flat bow-type or self-supporting and FRP or steel members to meet span and isolation needs.
| Option | Typical | Benefit |
|---|---|---|
| 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 aligns runs to your schedule and provides docs that detail final specs for straightforward QA on site.
Quality assurance, testing, and documentation
Shanghai Weiye OFC Equipment builds checkpoints into production so every item has recorded acceptance data at ship.
Environmental and Mechanical Tests
Our lab runs elevated-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials and assemblies. These tests recreate field stresses for indoor/outdoor applications.
Full Test Reports for Every Reel
Every fiber optic cable includes 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 claims are easy to verify. Documentation follows common customer templates to speed approvals and inbound inspection.
- In-line checks plus final inspection prevent field failures and cut warranty events.
- Quality packages include specifications confirmation and formatted test data for rapid review.
- Continuous test trends inform preventive maintenance and raise long-term reliability.
| Trial | Why | Outcome |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt spray | Corrosion robustness | Outdoor suitability |
| Vibration | Resistance to vibration | Improved field reliability |
FTTH Drop Cable Pricing & Cost Drivers
Budgeting for a drop run begins with fiber/jacket selection and is refined by volume and customization.
Typical prices vary widely—from about $30 to $1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket chemistry (LSZH, PVC, PE), length, and design structure.
Material choices, fiber grade, jacket type, and structure
The primary cost drivers are fiber optic grade, jacket material, and the chosen structure for deployment.
Self-supporting designs and steel strength elements raise material and labor input. Custom colors, logos, and print legends add setup time and influence price for short runs.
Order length, volume, and customization impact on price
Longer reels and higher volume orders lower unit cost. Small quantities often carry setup fees and higher unit prices.
- Line changeovers and custom tooling extend lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets over phases.
| Factor | Price impact | Guidance |
|---|---|---|
| Fiber grade | Large | Right-size spec to budget |
| Jacket type | Medium impact | Evaluate LSZH vs PE |
| Order length / volume | High impact | Consolidate runs to cut unit cost |
Logistics for the U.S.
Shanghai Weiye OFC Equipment keeps lead times/logistics clear so planners can align crews and sites. Predictable windows cut downtime and help control cost when a rollout is underway.
Scheduling & 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 provides updates/tracking so installation teams can plan arrivals. For tight schedules, we hold contingency capacity to accelerate critical-path orders.
MOQ and Rationale
The MOQ is one kilometer. This reflects setup needs such as wire/die adjustments that consume start-up material and scrap.
We review your put-ups and staging to choose reel sizes that cut waste and handling. Batch releases can balance inventory with frequent, smaller deliveries to job sites.
Where and How to Deploy
Site conditions determine 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 recommends self-supporting designs with appropriate members to control sag and tension for long-term reliability.
Duct installations perform best with low-friction sheaths 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 require proper depth control 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 cleanly and present controlled stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning exposure, and hardware fit. Standardized prep from the production line shortens install time and reduces scrap.
| Scenario | Key feature | Field note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Verify messenger hardware/tension |
| Duct | Low-friction jacket, crush resistance | Use pull tape + lubricant |
| Direct burial | PE with moisture barrier | Follow local depth and warning tape rules |
| Interior | LSZH jacket, tight bend support | Maintain bend radius at wall penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That reduces callbacks, faster activations, and reliable field performance for your system.
End-to-end support and after-sales service
Our team coordinates testing, scheduling, and installation guidance to remove surprises during deployment.
Shanghai Weiye OFC Equipment provides engineering support from early requirements capture 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 includes fast response, RCA, and corrective action. 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.
- Schedule coordination for expedites and urgent changes.
- Config control so shipped items match agreed requirements every time.
| Area | What we do | Outcome |
|---|---|---|
| Engineering | Specs + pilots | Fewer field issues |
| QA/Testing | Lab trials & 100% test reports | Full traceability |
| After-sales | Fast replace + RCA | Minimized downtime |
Final Thoughts
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 ships with a 100% test report and documented trials to support field acceptance in the United States.
A robust production line, including CLX-BPO2-enabled prep machines, cuts variability and speeds turnaround. Our equipment and machines standardize strip and 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 customer 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 shipment with laboratory validation and responsive service.