Flat Drop Cable Solves Capacity and Installation Delays for US Consumer Electronics

Case Study Highlights

Tubes with 5.96 fibers/mm²density - for compact FTTx builds
Gel-free dry tube design, saving time and consumables
1.35 kN tensilestrength, ICEA S-110-717standards
Lightweight, easy handling with compatibility for conventional wedge clamps and tools
Flat drop profile supporting up to 36 fibers

Overview

The 36F MLT Flat Drop Cable houses 36 fibers within the same footprint as a standard 24-fiber cable. By incorporating 12-fiber inside a dry subunit, the design achieves a remarkable fiber density of 5.96 fibers/mm², ensuring 33% higher capacity without expanding the cable size.

The gel-free dry construction simplifies splicing and termination, cutting installation time while maintaining superior mechanical strength (1.35 kN tensile rating) and long-term reliability. Its flat profile allows easy clamping, routing, and compatibility with conventional field tools.

Customer’s Overview

A leading U.S.-based consumer electronics and connectivity solutions company aimed to enhance its fiber optic network to support next-generation data and device communication needs. The goal was to increase fiber capacity, simplify installation, and ensure long-term durability all within the same compact infrastructure.

Partnering closely with the customer’s engineering team, HFCL designed and delivered the 36F MLT Flat Drop Cable, a sustainable, gel-free, and high-performance solution that delivers more fibers, faster installations, and reduced operational complexity for modern FTTx environments.

Challenges Faced

Compact Dry Tube Design

Developing a 12F dry tube while ensuring durability, fiber protection, and maintaining reliable excess fiber length (EFL) proved highly challenging.

Component Placement

Fitting multiple 12F dry tubes and water-swellable yarns (WSY) into a compact flat profile required precision placement to avoid compromising cable compactness and structural integrity.

Fiber Movement Control

Managing internal fiber stress and movement in dry tube construction was critical, as it directly impacts signal performance, durability, and long-term network reliability.

Tool Compatibility

The cable dimensions had to be precisely engineered to match Jonard FOD-2000 cable slitter specifications, ensuring effortless field usability and technician-friendly deployment

Tensile Strength

Achieving 1.35 kN tensile strength rating without increasing cable size or weight required innovative strength member design, balancing compact geometry with robust mechanical performance

HFCL’s Approach to These Challenges

Compact Dry Tube Development - Achieving a 12-fiber dry tube within a compact outer diameter demanded precise control over extrusion and EFL parameters.
Component Optimization - Tooling was redesigned and modified for precise tube and yarn positioning inside the cable core, ensuring accurate alignment and consistent manufacturing quality.
Fiber Movement Control - Compact dry tube dimensions, combined with controlled EFL, significantly limited fiber movement, confirmed through 56hr vibration and 30hr galloping tests using temporary fiber-access setups
Tool compatibility - Cable dimensions were engineered to be fully compatible with Jonard FOD-2000, allowing seamless operation with cable slitters and easy access to fibers
Mechanical Strength - Incorporation of two strength members reinforced the cable structure, achieving the required 1.35 kN tensile strength while maintaining a compact and efficient design.