Fiber optic cable trays, as a crucial carrier for laying fiber optic and other low-voltage cables, have their forming process directly determining their structural strength, dimensional accuracy, and service life.In the context of rapid iteration of information infrastructure, optimizing the forming process not only enhances the load-bearing capacity and adaptability of the trays but also provides a solid guarantee for high-density, high-reliability cabling.
Currently, mainstream fiber optic cable tray forming processes can be divided into two main systems: metal and non-metal. Metal trays mostly employ a combination of cold bending and welding processes. Cold bending involves bending metal sheets segment by segment according to a preset cross-section using continuous rolling equipment to form the tray profile. This process maintains good mechanical properties of the material and has high production efficiency. Subsequently, argon arc welding or high-frequency welding is used to seal and reinforce the joints or ends, ensuring overall rigidity and airtightness. To improve corrosion resistance, surface pretreatment and electrostatic spraying or hot-dip galvanizing are required after forming to enhance weather resistance and corrosion resistance.
Non-metal trays are mainly made of polymer composite materials and commonly employ extrusion molding and injection molding processes. Extrusion molding involves heating and melting granular or powdered raw materials, then continuously extruding them through a specific die to form a channel blank. The blank is then cooled and shaped to achieve the desired cross-sectional shape. This method is suitable for producing long, straight channels, offering advantages such as good consistency and high production capacity. For irregularly shaped components such as corners, end caps, and connectors, injection molding is used. High-precision molds are used for one-time forming, ensuring a perfect fit and assembly accuracy with the main channel. Some high-performance non-metallic channels also incorporate fiber reinforcement, adding glass or carbon fibers to the substrate to improve impact and creep resistance.
At the process control level, dimensional tolerances and geometric accuracy are particularly critical. Deviations in channel width, height, and wall thickness affect the smoothness of cable laying and the uniformity of load-bearing. Therefore, the molding process must be equipped with an online detection and feedback correction system. Simultaneously, the rounded transitions and surface finish at corners must be strictly controlled to prevent sharp edges from scratching cables or accumulating dust.
With the advancement of intelligent manufacturing, some molding processes have integrated CNC machining and automated assembly, significantly improving product consistency and production efficiency. The advancements in fiber optic cable routing technology have not only optimized product structural performance but also laid a reliable foundation for building a safe, clean, and scalable cable management system.