FTTH Drop Cable Production: Manufacturing Process Explained
Quick fact: more than 70% of new broadband deployments in the U.S. now use fiber networks that require tight manufacturing control to hit performance targets.
Shanghai Weiye OFC Equipment manages end-to-end fiber secondary coating line manufacturing, from selecting brand fibers like Fujikura® or Corning® SMF-28e to final test reports that deliver 100% QA.
Our drop designs are built for aerial, ducted, and direct-buried installation, with LSZH, PVC, and polyethylene (PE) jacket options and configurations from 1–4 cores. We offer single-mode OS1/OS2 and OM2–OM4 grades plus ITU-T G.652D and G.657 variants, Pantone-matched sheath colors, and custom logo printing.
Automation and precision equipment stabilize line speed and maximize repeatability. Typical lead times run 4–5 days for orders under 100 km and 7–10 days under 500 km, with an min. order of 1 km and free-replacement warranty for quality problems.
Read on to understand how our materials, tests, and support work together to reduce lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment delivers end-to-end manufacturing and lab testing for U.S. deployments.
- A range of jacket options and fiber grades support indoor/outdoor environments.
- Automated production lines ensure stable quality and reliable optical performance.
- Fast lead times, low MOQ, and recognized brand fibers keep procurement predictable.
- Complete reports and after-sales warranty support product reliability and documentation needs.
Expert FTTH manufacturing by Shanghai Weiye OFC Equipment
When deadlines and performance are critical, Shanghai Weiye OFC Equipment provides customized drop cables with complete test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment pairs purpose-built equipment with tight 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 conducts high-temperature, salt spray, and vibration tests to validate durability. Jacket options include LSZH, PVC, and PE. Designs cover bow-type flat and self-supporting styles and support brand fibers such as Fujikura and Corning SMF-28e.
- Controlled production lines and production checks for fully auditable shipments.
- Technical support for specification reviews, trials, and volume ramp.
- Modern fixtures and calibration minimize variation so every cable meets carrier standards.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, combining brand fiber choices with strict test routines.
Optical fiber selection and brand options
We select fiber ribbon line to minimum bend radius, attenuation, and install environment. 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.
Integrating Strength Members
Strength members employ FRP (dielectric) or metallic steel wire. FRP is preferred where non-conductive runs are required. Steel wire adds tensile strength for long-span aerial runs and grounding needs.
Jacket Options and Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility and ease of handling, and PE for UV/moisture resistance outdoors. Closed-loop control of extruder temperature and capstan speed keeps line speed stable and dimensional tolerances.
| Component | Dielectric FRP | Steel wire |
|---|---|---|
| Use case | Non-conductive runs | High-tension aerial runs |
| Key benefit | Lightweight, inert | High strength |
| Installation note | Easier terminations | Requires grounding |
In-Process and Final Testing
Inline geometry and concentricity checks operate in-line. Final optical tests verify attenuation and return loss. Each order ships with a 100% test report and lab results from high-temperature, salt fog, and vibration tests to confirm handling for drop terminations and field use.
Typical lead times are 4–5 days for < 100 km and under 500 km in 7–10 days. Lot records and FAI approvals provide traceability and compliance for U.S. programs.
FTTH drop cable types and structures we manufacture
Shanghai Weiye OFC Equipment provides a focused 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 bow-type flat drop cable minimizes footprint for risers/ducts. It reduces bend loss for simple routing in MDU corridors and hallways.
Self-supporting designs for aerial spans
Self-supporting FTTH drop designs include a support messenger to carry tensile loads. Choose dielectric FRP for electrical isolation or steel wire when bonding/grounding and extra tensile strength are required.
Strength member and core layouts
We offer dielectric and metallic strength member configurations to meet safety/EMI requirements. Center loose tube and flat unitube types balance crush resistance and fiber secondary coating line for fast terminations.
Indoor/outdoor jackets
Jacket choices include LSZH for flame-retardant, low-smoke indoor use and PE for outdoor durability. Each series is validated for mechanical and optical quality before shipment.
| Design | Application | Strength element | Sheath |
|---|---|---|---|
| Flat bow-type | Indoor risers and MDUs | FRP (dielectric) | Low-smoke zero-halogen |
| Self-supporting (aerial) | Aerial spans | FRP/Steel | PE |
| Central loose-tube | Higher fiber counts | Dielectric FRP | LSZH or PE |
| Flat unitube | Low count, quick strip | FRP/Steel | LSZH/PE |
Production line equipment that ensures quality and speed
Automation and sensor-driven 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 reduce operator variability.
The CLX-BPO2 auto-stripping machine uses PLC + photoelectric control. One cycle is about 1.5 seconds, giving ~20 terminals per minute in production.
Auto Cut & Strip Capabilities
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise reserved lengths. Pneumatic cylinder actuators provide quick, repeatable motion and minimize downtime.
Closed-Loop Control for Repeatability
PLC logic and photoelectric sensors give exact positioning and closed-loop control. Inline checks feed control charts so operators can adjust drifts before defects grow.
| Feature | Capability | Benefit |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Pneumatic cylinders | High speed and reliability |
| Materials | LSZH/PVC; FRP/steel | Clean, accurate preps |
| Control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Automated waste ejection and ergonomic loading maintain clean workcells.
- PCPs document calibration and key parameters.
- Combined machines, fixtures, and trained staff support FTTH volume targets 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 raise output and standardize terminal quality. The unit cycles in ~1.5 seconds, producing around 20 preps 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.
Line Speed
Typical operation speed is 1.5s per cycle. This translates to steady throughput under normal production conditions.
Supported Strip and 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 cleanly cuts FRP and steel wire strength elements while protecting adjacent fibers. Custom tooling are offered for non-standard cross-sections to preserve precision.
- Automatic waste ejection and sensor-triggered start reduce idle time.
- Compact size (L40 × W18 × H18 cm), 50W at 110–220V, and 11 kg mass simplify cell integration.
- Cylinder-driven motion and closed-loop control improve line reliability and lower maintenance interruptions.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | High throughput for production runs |
| Jacket strip (A) | 17.5 to 35.0 mm | Fits common connector processes |
| Stub (B) | 7.0 to 11.0 mm | Meets strength and termination needs |
| 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 get drop parts install-ready. The CLX-BPO2 supports our lines in meeting volume targets without compromising quality.
Customized specifications to fit your FTTH system
Shanghai Weiye OFC Equipment configures every order to meet your network requirements and simplify field rollout. We pair concise options with predictable manufacturing windows so your teams receive ready-to-install products.
Choose 1 to 4 cores with SM or MM fiber. Options include OS1, OS2, and OM2–OM4 plus G.652D and G.657 variants to match your optics and connector plans.
We match sheath colors to Pantone codes for quick field identification and consistent asset tags.
Branding and Print Options
Select LSZH/PVC/PE jackets to suit route and safety requirements. Custom legends/logos support inventory and warranty tracking.
Put-Ups, Packaging, and Structures
Standard reel lengths 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 meet span and isolation needs.
| Option | Common choice | Advantage |
|---|---|---|
| Reel length | 1, 2, or 4 km | Less staging, easier reels |
| Jacket | LSZH, PE, PVC | Indoor/outdoor compatibility |
| Design | Bow-type / Self-supporting | Routing and span flexibility |
As a supplier, Shanghai Weiye aligns runs to your schedule and delivers documentation that lists final specifications for straightforward QA on site.
Quality, Test, and Docs
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 runs high-temperature exposure, salt spray corrosion, and mechanical vibration to qualify materials and assemblies. These tests simulate field stresses for indoor/outdoor applications.
Per-Reel 100% Reports
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 claims are easy to verify. Documentation uses standard customer templates to speed approvals and inbound inspection.
- Line checks and final inspection reduce field failures and lower warranty events.
- QA packages include spec confirmation and formatted data for rapid review.
- Ongoing trend analysis drive preventive maintenance and raise long-term reliability.
| Trial | Purpose | Result |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt-fog | Corrosion resistance | Outdoor suitability |
| Mechanical vibration | Mechanical robustness | Improved field reliability |
Cost Drivers and Pricing
Budgeting for a drop run begins with fiber/jacket selection and is refined by volume and customization.
Typical prices range broadly—from about $30–$1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket material, 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 and impact pricing on small runs.
Length/Volume/Customization Impact
Longer put-ups and larger volumes reduce unit cost. Short runs often include setup charges and higher per-unit charges.
- Line changeovers and custom tooling increase lead time and add to cost.
- Clear RFQs and line scheduling let Shanghai Weiye OFC Equipment align price quotes to delivery windows.
- Frameworks and indexed pricing stabilize budgets across phases.
| Driver | Price impact | Guidance |
|---|---|---|
| Optical grade | Large | Balance spec vs. budget |
| Sheath material | Medium | Evaluate LSZH vs PE |
| Length/Volume | Large | Consolidate where possible |
U.S. Lead Times, MOQ & Delivery
Shanghai Weiye OFC Equipment makes lead times and logistics clear so planners can align crews and sites. Predictable schedules cut downtime and control costs 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 provides updates/tracking so installation teams can plan arrivals. For compressed schedules, we hold contingency capacity to pull in critical-path orders.
Why MOQ Matters
The MOQ is 1 km. This reflects line setup such as wire and jacket die adjustments that use startup material and generate scrap.
We review your length and staging plans to select reels to reduce waste/handling. Batch releases can balance inventory holding with more frequent small-site deliveries.
Installation readiness and application scenarios
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 manage sag/tension for long-term reliability.
Duct installations work best with low-friction sheaths and crush-resistant builds so pulling does not damage fibers. 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 barriers to protect the optic core over time.
Indoor Distribution and ONT
Indoor riser and plenum routes prefer LSZH to meet flame and smoke rules. 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 fit. Standardized line prep reduces install time and minimizes scrap.
| Deployment | Key feature | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Check tension and messenger hardware |
| Underground duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct burial | PE jacket, moisture barrier | Follow depth/warning tape codes |
| Interior | LSZH jacket, tight bend support | Maintain bend radius at penetrations |
Our approach ensures a consistent install experience across indoor outdoor transitions. That reduces callbacks, speeds activations, and reliable field performance for your system.
Support from Spec to Service
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 pilot builds. We deliver documentation templates and clear install notes so field crews share a unified 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.
- Round-the-clock availability for status updates and technical guidance.
- Warranty includes free replacement for confirmed quality issues.
- Coordination of line schedules for expedites and urgent changes.
- Configuration control so shipped items match agreed specs consistently.
| Support area | Scope | Outcome |
|---|---|---|
| Tech/Eng | Spec review & pre-production builds | Reduced field issues |
| QA/Testing | Lab trials & 100% test reports | Traceable quality |
| Service | Fast replace + RCA | 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 ships with a 100% test report and documented trials to support U.S. field acceptance.
A hardened production line, including CLX-BPO2 prep assets, cuts variability and shortens turnaround. Our equipment set standardize strip/stub lengths so installers get consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance design and cost to maximize service life. Dedicated support guides scheduling, logistics, and after-sales care 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 laboratory validation and responsive support.