FTTH Drop Cable Production: Manufacturing Process Explained
Surprising fact: more than seventy percent of new U.S. broadband builds now rely on fiber networks that need tight manufacturing control to meet performance goals.
Shanghai Weiye OFC Equipment handles end-to-end SZ stranding line manufacturing, from choosing brand fibers like Fujikura® or Corning SMF-28e to comprehensive test documentation that deliver 100% QA.
Our drop designs are built for aerial, underground, and direct burial installation, with low-smoke zero-halogen (LSZH), PVC, and polyethylene (PE) jacket options and configurations from 1 to 4 cores. We supply single-mode OS1/OS2 and multimode OM2–OM4 grades plus G.652D and ITU-T G.657 variants, Pantone sheath colors, and logo printing.
Automation and precision equipment stabilize line speed 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 MOQ of 1 km and free-replacement warranty for quality problems.
Keep reading to understand how materials plus testing and support combine to lower lifecycle cost and pair the right product with your network.
- Shanghai Weiye OFC Equipment offers end-to-end manufacturing and lab testing for U.S. deployments.
- A range of jacket options and optical grades fit indoor/outdoor environments.
- Automated production lines ensure stable quality and stable optical performance.
- Fast lead times, low MOQ, and brand fiber options support reliable procurement planning.
- Comprehensive test reports and warranty support product reliability and compliance documentation needs.
FTTH Manufacturing Expertise by Shanghai Weiye OFC Equipment
When schedules and performance count, Shanghai Weiye OFC Equipment provides customized drop cables with complete test documentation.
As a focused supplier and manufacturer, Shanghai Weiye OFC Equipment combines purpose-built equipment with tight material control. We offer custom builds and services for residential/MDU deployments. Every order includes 100% quality assurance and full test reports.
Our lab runs high heat, salt spray, and vibration testing to verify durability. Jacket options cover LSZH, PVC, and PE. Designs offer bow-type flat and 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.
- Engineering support for requirements, pilots, and scaling.
- Modern fixturing and calibration reduce variability so every cable matches operator specs.
FTTH Cable Production
At Shanghai Weiye OFC Equipment, manufacturing steps are matched to network specs, pairing brand fiber choices with strict test routines.
Optical fiber selection and brand options
We select Fiber coloring machine to minimum bend radius, attenuation, 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 satisfy sourcing standards.
Strength member integration
Strength members use FRP (dielectric) 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.
Extrusion & Process Control
Jacket options include LSZH for flame/smoke safety, PVC for flexibility, and PE for UV/moisture resistance outdoors. Tight process control of extruder temperature and capstan speed keeps line speed stable and critical dimensions.
| Member | FRP | Metallic Steel |
|---|---|---|
| Primary use | Electrical isolation | High-tension aerial runs |
| Advantage | Light, non-corrosive | High strength |
| Installation note | Easier terminations | Bonding/grounding required |
In-Process and Final Testing
Inline geometry and concentricity checks operate in-line. Final optical tests verify loss and return loss. Each order ships with a full test report and lab results from high-temperature, salt fog, and vibration tests to qualify field handling and drop terminations.
Typical lead times are under 100 km in 4–5 days and 7–10 days for < 500 km. Lot records and first-article 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 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 reduces bend loss for simple routing in MDU corridors and hallways.
Self-Supporting Aerial Designs
Self-supporting FTTH drop designs use a messenger element to carry tensile loads. Choose dielectric FRP for non-conductive runs or steel messenger when bonding/grounding and extra tensile strength are required.
Core Layouts and Strength Members
We offer dielectric and metallic strength member configurations to match safety and EMI rules. Center loose tube and flat unitube types balance crush resistance and fiber secondary coating line 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 series is qualified for mechanical/optical performance before shipment.
| Design | Application | Strength element | Jacket |
|---|---|---|---|
| Flat bow-type | Indoor risers, MDUs | FRP (dielectric) | LSZH |
| Self-supporting (aerial) | Overhead spans | Steel wire or FRP | Polyethylene |
| Center loose tube | Higher fiber counts | FRP | LSZH or PE |
| Unitube flat | Low-count, easy strip | FRP or steel | LSZH or PE |
Production line equipment that ensures quality and speed
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 cut labor 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 Cut/Strip for Drop Cords
The equipment strips LSZH/PVC jackets and trims FRP/steel members to precise reserved lengths. Cylinder-driven actuators deliver fast, repeatable motion and low downtime.
Closed-Loop Control for Repeatability
PLC logic + photoelectric sensors give exact positioning and closed-loop control. Inline checks feed control charts so operators can adjust drifts before defects grow.
| Item | Spec | Result |
|---|---|---|
| CLX-BPO2 | Auto-strip, ~1.5 s cycle | High throughput |
| Actuation | Cylinder-based | High speed and reliability |
| Material handling | LSZH/PVC; FRP/steel | Accurate stubs, clean terminations |
| 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.
- Integrated assets and trained operators support FTTH volume targets without sacrificing accuracy.
CLX-BPO2 auto-stripping machine capabilities in 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 uses the CLX-BPO2 to increase throughput and standardize prep 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 keeps strip and stub lengths within tight tolerances.
Line Speed
Typical operation speed is ~1.5 seconds per cycle. This converts to steady throughput under continuous line conditions.
Supported Strip and 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 set between 7.0 and 11.0 mm to fit common termination hardware.
FRP & Steel Member Handling
The machine cleanly cuts FRP and steel wire strength elements while protecting neighboring fibers. Customized cutters are available for nonstandard sizes to preserve precision.
- Automatic waste ejection and sensor-triggered start reduce idle time.
- Small footprint (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 reduce maintenance downtime.
| Spec | Value | Why it matters |
|---|---|---|
| Cycle time | ≈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 to 11.0 mm | Meets strength and termination needs |
| Power & size | 110–220V, 50W; 40×18×18 cm | Simple integration |
Using this machine, Shanghai Weiye OFC Equipment standardizes prep so field teams receive drop parts ready for quick installation. The CLX-BPO2 helps our production lines meet volume goals without sacrificing quality.
Custom Specs for Your FTTH System
Shanghai Weiye OFC Equipment configures every order to fit your network requirements and simplify field rollout. We pair concise options with predictable manufacturing windows so your teams get install-ready reels.
Choose 1–4 core designs with SM or MM fiber. Options include OS1, OS2, and OM2–OM4 plus 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.
Branding and Print Options
Select LSZH/PVC/PE jackets based on route and safety rules. Custom legends/logos support inventory and warranty tracking.
Length options, packaging, and special structures
Standard put-ups are 1 km, 2 km, and 4 km with tailored reels and packaging to fit storage/handling. Choose bow-type flat or self-supporting designs and steel wire or FRP strength members to meet span and isolation needs.
| Option | Common choice | Benefit |
|---|---|---|
| Reel length | 1, 2, or 4 km | Less staging, easier reels |
| Sheath | LSZH, PE, PVC | Indoor/Outdoor fit |
| Design | Flat bow / Self-supporting | Routing and span flexibility |
As a manufacturer, Shanghai Weiye schedules runs to your plan and provides docs that detail final specs for straightforward QA on site.
QA, Testing & Documentation
Shanghai Weiye OFC Equipment embeds quality checkpoints across the production line 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 vibration tests to qualify materials/assemblies. These tests recreate 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 stop nonconforming items before they leave the factory.
Traceability and 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.
- 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 drive preventive maintenance and improve long-term reliability.
| Test | Why | Result |
|---|---|---|
| High-temperature | Thermal stability | Pass at target temperature |
| Salt spray | Corrosion robustness | 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 to $1,000 per unit—based on fiber grade (G.652/G.657/OM2–OM4), jacket chemistry (LSZH, PVC, PE), reel length, and structural design.
Primary Cost Inputs
The primary cost drivers are fiber grade, sheath material, and the structural type chosen for deployment.
Self-supporting designs and steel members raise material and labor input. Custom colors, logos, and print 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. Small quantities often include setup charges and higher per-unit charges.
- Line changeovers and custom tooling extend 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 over phases.
| Driver | Effect on price | Recommendation |
|---|---|---|
| Optical grade | Large | Right-size spec to budget |
| Sheath material | Medium impact | Evaluate LSZH vs PE |
| Length/Volume | Large | Consolidate runs to cut unit cost |
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.
Scheduling & Capacity Planning
Typical production windows are 4–5 days for < 100 km and 7–10 days for orders under 500 km. We plan 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 compressed schedules, we reserve contingency capacity to accelerate critical-path orders.
Why MOQ Matters
The MOQ is 1 km. This reflects setup needs such as wire/die adjustments that use startup material and generate scrap.
We review your put-ups and staging to choose reel sizes that cut waste and handling. Batch releases can balance inventory holding with frequent, smaller deliveries to job sites.
Installation Scenarios & Readiness
Site conditions determine 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 recommends self-supporting designs with correct strength 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 typical 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 riser/plenum distribution and ONT termination
Indoor riser and plenum routes prefer LSZH to meet smoke/flame codes. Flat drop cable forms strip cleanly and present controlled strength stubs for fast ONT terminations.
We advise on steel vs FRP (dielectric) strength members based on bonding needs, lightning risk, and hardware compatibility. Standardized line prep shortens install time and reduces scrap.
| Deployment | Key feature | Installer note |
|---|---|---|
| Overhead | Self-supporting, steel or FRP | Check tension and messenger hardware |
| Underground duct | Low-friction, crush-resistant | Use pull tape + lubricant |
| Direct burial | 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, faster activations, and stable 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 offers engineering support from early requirements capture through approved drawings and pre-production 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 with free replacement if any quality problems are confirmed.
- Schedule coordination for urgent changes or acceleration requests.
- Configuration control so shipped items match agreed requirements every time.
| Area | Scope | Outcome |
|---|---|---|
| Engineering | Spec review & pre-production builds | Reduced field issues |
| QA/Testing | Lab + 100% reports | Traceable quality |
| After-sales | Rapid replacement & root-cause | Minimized downtime |
Conclusion
Choose Shanghai Weiye OFC Equipment for tailored drop builds, short lead times, and traceable quality records.
We provide custom FTTH drops 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 robust production line, including CLX-BPO2-enabled prep machines, reduces variability and speeds turnaround. Our equipment and machines standardize strip and stub lengths so installers get consistent results at turn-up.
From fiber selection through jacket, printing, and packaging, we balance design and cost to extend 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 lab validation and responsive support.
