FTTH Drop Cable Production: How the Manufacturing Process Works
Surprising fact: more than 70% of U.S. broadband rollouts now rely on fiber networks that demand high-precision manufacturing to hit performance targets.
Shanghai Weiye OFC Equipment manages complete fiber secondary coating line manufacturing, from choosing brand fibers like Fujikura® or Corning SMF-28e to complete test reports that ensure 100% quality assurance.
Our drop cable designs suit overhead, underground, and direct burial installation, with LSZH, PVC, and polyethylene (PE) jacket options and core counts from 1–4 cores. We supply OS1/OS2 and OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone-matched sheath colors, and logo printing.
Automation and precision equipment keep line speed steady and keep repeatability high. Typical lead times are four to five days for orders < 100 km and 7–10 days under 500 km, with an min. order of 1 km and warranty for free replacement on quality issues.
Continue to see how materials, testing, and support help reduce lifecycle cost and align the product to your network needs.
- Shanghai Weiye OFC Equipment delivers complete production and laboratory testing for U.S. deployments.
- Multiple jacket choices and fiber grades cover different install environments.
- Automated production lines provide consistent quality and stable optical performance.
- Quick lead times, low MOQ, and brand fiber options help plan procurement reliably.
- Comprehensive test reports and warranty support product reliability and documentation needs.
FTTH Manufacturing Expertise 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 dedicated manufacturer, Shanghai Weiye OFC Equipment pairs specialized equipment with stringent material control. We provide custom builds and services for residential/MDU deployments. Every order comes with 100% quality assurance and complete test reports.
Our lab runs 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.
- Engineering support for specification reviews, trials, and volume ramp.
- Modern fixtures and calibration reduce variability so every cable meets carrier standards.
FTTH cable production
At Shanghai Weiye OFC Equipment, manufacturing steps are aligned to network specifications, pairing brand fiber choices with disciplined test flows.
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 available to meet procurement standards.
Strength member integration
Strength members use dielectric FRP or metallic 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 UV/moisture resistance outdoors. Tight process control of temperature and capstan ratios stabilizes line speed and dimensional tolerances.
| Member | Dielectric FRP | Metallic Steel |
|---|---|---|
| Primary use | Non-conductive runs | Aerial spans, high tensile |
| Key benefit | Light, non-corrosive | Very high tensile strength |
| Installation note | Easier terminations | Requires grounding |
Inline and final testing
Inline geometry/concentricity checks run during manufacturing. Final optical tests confirm attenuation and reflectance. Each order includes a full test report and lab results from high heat, salt fog, 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. 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 combines tested materials with field-termination geometry and stable optical performance.
The bow-type flat drop cable minimizes footprint for risers and conduit. It keeps bend loss low for simple routing in hallways and MDUs.
Aerial Self-Supporting Options
Self-supporting FTTH drop designs include a support messenger to handle tension. Choose FRP (dielectric) for electrical isolation or steel messenger when bonding/grounding and extra tensile strength are required.
Layouts & Strength Members
We offer both 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 quick termination.
Jackets for Indoor/Outdoor
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.
| Type | Best use | Strength element | Jacket |
|---|---|---|---|
| Bow-type flat | Indoor risers, MDUs | Dielectric FRP | LSZH |
| Self-supporting | Overhead spans | Steel wire or FRP | Polyethylene |
| Central loose-tube | Higher fiber counts | FRP | LSZH or PE |
| Flat unitube | Low-count, easy strip | FRP or steel | LSZH/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 uses automated machines that cut/strip drop cords to increase output and reduce operator variability.
The CLX-BPO2 auto-stripping machine runs under PLC and photoelectric control. One cycle is about 1.5 seconds, giving real-world speeds near 20 terminal operations per minute.
Automated cutting and stripping for drop cable patch cords
The equipment strips LSZH and PVC jackets and trims FRP or steel strength members to precise stub lengths. Cylinder-driven actuators deliver fast, repeatable motion and low downtime.
Closed-Loop Control for Repeatability
PLC logic and photoelectric sensors give exact positioning and closed-loop control. Inline checks update SPC charts so operators can adjust drifts before defects grow.
| Item | Spec | Result |
|---|---|---|
| Machine | 1.5s cycle, auto-strip | ~20 terminals/minute throughput |
| Drive | Cylinder-based | High speed and reliability |
| Materials | LSZH/PVC; FRP/steel | Clean, accurate preps |
| Process control | PLC + photoelectric + inline checks | Stable quality, reduced rework |
- Automated waste ejection and ergonomic loading keep the line clean.
- Process control plans 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 provides industrial-grade strip/trim to our line, cutting cycle time while maintaining consistent prep.
Shanghai Weiye OFC Equipment uses the CLX-BPO2 to increase throughput and standardize terminal quality. The unit cycles in ~1.5 seconds, producing around 20 preps per minute in production.
PLC/photoelectric control deliver exact detection and repeatable motion. That control helps keep strip lengths and reserved strength stubs within tight tolerances.
Cycle time and throughput
Typical operation speed is ~1.5 seconds per cycle. This translates to steady throughput under continuous line conditions.
Supported jacket and reserved strength lengths
The CLX-BPO2 handles LSZH/PVC with an adjustable strip length from 17.5–35.0 mm. Reserved strength member stubs are adjustable from 7.0–11.0 mm to fit common termination hardware.
Cutting FRP/Steel Members
The machine cuts FRP/steel strength elements cleanly while protecting adjacent fibers. Customized cutters are available for non-standard cross-sections to preserve precision.
- Auto-eject scrap and sensor-triggered start cut idle time.
- Small footprint (L40 × W18 × H18 cm), 110–220V, 50W, and 11 kg mass ease integration into workcells.
- Cylinder-driven motion and closed-loop control improve line reliability and lower maintenance interruptions.
| Spec | Rating | Why it matters |
|---|---|---|
| Cycle | ~1.5 s (~20/min) | Supports high-volume 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 | 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.
Custom Specs for Your FTTH System
Shanghai Weiye OFC Equipment configures every order to meet your network requirements and simplify deployment. We combine focused options with predictable schedules so your teams receive ready-to-install products.
Choose 1–4 core designs with single-mode or multimode fiber. Options include OS1, OS2, and 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/PE jackets based on route and safety rules. Custom print legends and logos aid inventory/warranty tracking.
Lengths, Packaging & Special Builds
Standard put-ups are 1 km, 2 km, and 4 km with tailored 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 | Typical | Benefit |
|---|---|---|
| Reel length | 1 / 2 / 4 km | Simpler staging and reels |
| Sheath | LSZH, PE, PVC | Indoor/Outdoor fit |
| Structure | Bow-type / Self-supporting | Flexible routing/span |
As a manufacturer, Shanghai Weiye aligns runs to your schedule and provides docs that detail final specs for straightforward QA on site.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment builds checkpoints into production so every item has recorded acceptance data at ship.
High-temperature, salt spray, and vibration laboratory testing
Our lab runs elevated-temperature exposure, salt fog corrosion, and mechanical vibration to qualify materials/assemblies. These tests simulate field stresses for indoor/outdoor applications.
Per-Reel 100% Reports
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.
Audit Trail and Compliance
Batch records link tests to reels/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 reduce field failures and lower warranty events.
- QA packages include specifications confirmation and formatted data for quick review.
- Continuous test trends drive preventive maintenance and improve long-term reliability.
| Test | Purpose | Outcome |
|---|---|---|
| High-temperature | Material stability | Validated heat endurance |
| Salt-fog | Corrosion robustness | Outdoor suitability |
| Vibration | Resistance to vibration | Reduced field failures |
Pricing and cost drivers for FTTH drop cable
Budget planning for a drop 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 structural design.
Primary Cost Inputs
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 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 lower unit cost. Small quantities often include setup charges and higher per-unit charges.
- Changeovers and special cutters increase lead time and add to cost.
- Clear RFQs with schedule alignment let Shanghai Weiye OFC Equipment match quotes to delivery windows.
- Framework agreements and indexed pricing stabilize budgets across phases.
| Driver | Price impact | Recommendation |
|---|---|---|
| Optical grade | High impact | Right-size spec to budget |
| Jacket type | Medium | Compare LSZH vs. PE for total cost |
| Order length / volume | Large | 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 crews and sites. Predictable windows reduce downtime and control costs when a rollout is underway.
Production Windows & Capacity
Typical production windows are 4–5 days for < 100 km and 7–10 days for orders under 500 km. We schedule line capacity to track your milestones and to maintain on-time delivery.
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.
Why MOQ Matters
The MOQ is one kilometer. 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. Batch releases can balance inventory holding with more frequent small-site deliveries.
Installation readiness and application scenarios
On-site conditions dictate whether a self-supporting span, 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 appropriate members to control sag and tension for long-term stability.
Duct installations perform best with low-friction jackets and crush-resistant builds 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-resistant jackets to protect the optic core over time.
Indoor Riser/Plenum & 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 quick ONT termination.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning exposure, and hardware fit. Standardized line prep shortens install time and minimizes scrap.
| Deployment | Key feature | Field note |
|---|---|---|
| Overhead | Self-supporting (steel/FRP) | Verify messenger hardware/tension |
| Underground duct | Low-friction, crush-resistant | Use pull tape and proper 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 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 provides engineering support from early requirements capture 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 test reports and traceability to help QA acceptance.
- 24/7 availability for status and technical support.
- Warranty with free replacement if any quality problems are confirmed.
- Schedule coordination for expedites and urgent changes.
- Config control so shipped items match agreed specs consistently.
| Support area | What we do | Outcome |
|---|---|---|
| Engineering | Specs + pilots | Reduced field issues |
| QA/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 deliver customized FTTH drop solutions that pair material choices with validated manufacturing and lab testing. Every reel includes a 100% test report and documented lab trials to support field acceptance in the United States.
A hardened production line, including CLX-BPO2 prep assets, cuts variability and shortens turnaround. Our equipment set standardize strip/stub lengths so installers see consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance performance and cost to maximize service life. Dedicated support guides scheduling, logistics, and after-sales care so your deployment stays on plan.
Get in touch with Shanghai Weiye OFC Equipment to align specifications, timeline, and volume. We stand behind every fiber optic and optic cable shipment with lab validation and responsive support.