Project Background
Abalone Technology was tasked by a German telecom client to develop an indoor PTO kit with a 30-meter pre-connected optical cable. Though designed for indoor use, the product needed to meet stringent performance, UV resistance, and cost control requirements.
Project Challenge
Project Challenge 1: High-Performance Cable & Cost Control
Reason: On-site technicians found that pushing cables into conduits required machines and tools, which was inefficient. Traditional patch cords were too soft, so they requested a cable that could be pushed by hand.
Customer requirements:
- Pass B2CA certification
- Diameter 2.3mm, manually inserted into 20mm conduit over 10+ meters
- Cost comparable to standard B2CA cables
Technical difficulty: Combining rigidity and low friction in a thin cable while controlling cost required multiple material formulation tests.
Project Challenge 2: UV-Protected Box & Flip Cover Design
Reason for flip cover: Protect fiber interface from dust and damage, maintain neat appearance, and provide smooth opening with damping.
Customer requirements:
- UV resistance for indoor use
- Flip cover integrated with spring mechanism
Technical difficulty:
- UV additives softened plastic, risking deformation under spring force
- RoHS/REACH limited material choices
- Adjusting thickness affected mold tolerances and assembly
- Reducing spring force compromised damping effect
Project Detail
Abalone conducted multiple rounds of material testing to:
- Optimize the cable’s rigidity
- Reduce friction
- Ensure cost-efficiency
For the terminal box:
- Tested five combinations of raw materials and UV agents
- Balanced durability, appearance, and regulatory compliance
Project Outcome
Delivered:
- Cost-effective
- UV-resistant
- Mechanically robust indoor PTO kit
Achieved:
- B2CA certification
- Stable spring performance
- Cost savings through in-house lab validation and supply chain optimization
Customer Feedback
“I am a procurement manager working closely with Deutsche Telekom. I approached many suppliers with this challenging request, but none were willing to take it on. Only Abalone stepped up and delivered exactly what we needed. They solved every technical hurdle while keeping costs under control. I truly appreciate their commitment and expertise, and this solution is now being considered for wider deployment.”
