Custom DC Plug & Socket Cable Assembly Manufacturer

Yihetai manufactures custom DC plug and socket cable assemblies for power adapters, LED lighting, CCTV cameras, industrial equipment, consumer electronics, smart devices and low-voltage power systems. From prototype samples to volume production, we help you build reliable DC power connections that match your exact application requirements.

OEM/ODM DC power cable assemblies with custom plug size, socket type, wire gauge, cable length, polarity, jacket material and molded strain relief.

What Is a DC Plug & Socket Cable Assembly?

A DC plug and socket cable assembly is a customized cable used to transmit low-voltage DC power between a power source and an electronic device. It usually includes a DC barrel plug, DC female jack, panel mount socket, right angle connector, molded strain relief, insulated wires and optional terminals or connectors on the other end.

These assemblies are commonly used when equipment requires a stable, compact and easy-to-install DC power interface. The cable can be customized according to connector size, polarity, wire gauge, cable length, jacket material, molding shape, color and application environment.

Yihetai focuses on custom manufacturing, which means your DC plug socket cable can be produced according to your exact design instead of being limited to standard off-the-shelf cable options.

DC Plug & Socket Cable Types We Manufacture

Yihetai manufactures a wide range of custom DC plug and socket cable assemblies for different electrical and mechanical designs.

1. DC Male Plug to Female Socket Cable
A DC male plug to female socket cable is commonly used as an extension cable between a power adapter and an electronic device. Yihetai can customize the plug size, cable length, wire gauge, polarity, and jacket material according to your power requirements and installation environment.

2. DC Plug to Open-End Wire Cable
DC plug to open-end wire cables are suitable for connecting power adapters to internal wiring, terminal blocks, PCB boards, LED modules, and control systems. The wire ends can be stripped, tinned, crimped, soldered, or assembled with terminals based on your production needs.

3. DC Socket to Wire Harness Assembly
DC socket cable assemblies are often used inside electronic devices, control boxes, smart equipment, lighting systems, and charging devices. We can provide panel mount DC sockets, inline DC sockets, overmolded DC sockets, and DC jack cable assemblies with customized mounting structures.

4. Right-Angle DC Plug Cable
Right-angle DC plug cable assemblies are ideal for compact spaces where straight connectors may cause bending stress or interfere with enclosure design. Yihetai can customize 90-degree DC plug cables with different plug sizes, molding dimensions, and cable exit directions.

5. Overmolded DC Plug & Socket Cable
Overmolded DC plug and socket cables provide improved strain relief, better appearance, and more stable mechanical performance for repeated use. Yihetai supports custom mold design, PVC/TPE overmolding, color customization, logo marking, and production according to your approved samples or drawings.

6. DC Plug Cable with Additional Connectors
For OEM equipment, a DC plug cable may need to connect to other terminals or connectors inside the device. Yihetai can manufacture DC plug cable assemblies with JST connectors, Molex connectors, Dupont connectors, ring terminals, spade terminals, Faston terminals, waterproof connectors, USB connectors, or custom terminal blocks.

7. DC Male to Female Extension Cable
A DC male-to-female extension cable is used to extend the connection distance between a power source and a device. Yihetai can customize extension cables with different lengths, wire gauges, current ratings, plug sizes and molding designs. Common applications include LED lighting systems, CCTV cameras, routers, sensors, smart home devices and portable equipment.

Reliable DC Power Cable Assemblies Built to Your Specification

DC plug and socket cable assemblies are widely used for low-voltage DC power transmission between adapters, control boards, LED modules, cameras, sensors, routers, chargers and industrial devices. A small difference in plug size, current rating, cable gauge or polarity can cause unstable power supply, overheating, loose connection or field failure.

Yihetai provides custom DC cable assembly solutions based on your electrical, mechanical and environmental requirements. Whether you need a simple DC pigtail cable, a molded DC male-to-female extension cable, a right-angle DC plug, a panel-mount DC socket harness, or a multi-branch DC power cable, our engineering and production teams can support your design from sample development to mass production.

Technical Specifications

Item	Specification
Product Name	Custom DC Plug Socket Cable Assembly
Connector Type	DC male plug / DC female socket / panel mount DC socket
Common Plug Sizes	5.5 x 2.1 mm, 5.5 x 2.5 mm, customized sizes
Cable Type	DC power cable, extension cable, pigtail cable, panel-mount cable
Wire Gauge	Typical 18–24 AWG, customized by current and design
Conductor	Bare copper / tinned copper
Jacket Material	PVC / TPE / PUR / customized
Cable Length	Customized
Color	Black, red/black, white, or custom
Structure	Straight / right-angle / panel mount / overmolded / stripped-end
Voltage Application	Low-voltage DC applications, defined by connector and cable design
Current Capacity	Customized according to connector size, cable gauge, and application
Temperature Range	Customized according to selected wire and jacket material
Optional Features	Shielding, waterproofing, labeling, protective cap, overmolding
Testing	Continuity test, polarity check, open/short test, visual inspection, dimensional check, hi-pot if required

Typical Applications

Custom DC plug and socket cable assemblies are widely used in low-voltage power connectionapplications across lighting, security, industrial, consumer electronics, medical devices and energy systems.

How to Specify a Custom DC Plug & Socket Cable Assembly

To ensure the correct DC cable design, please confirm the following information before quotation:

1. Connector Size

Please provide the outer diameter, inner diameter and barrel length of the DC plug or socket. Common options include 5.5×2.1mm and 5.5×2.5mm, but other sizes are also available.

2. Polarity

Please confirm whether the cable is center-positive, center-negative or requires a custom polarity layout.

3. Voltage and Current

The cable design should match the rated voltage and current of the application. Wire gauge, cable length and connector rating should be selected to reduce voltage drop and overheating risk.

4. Cable Length

The total cable length and tolerance should be confirmed according to installation space and routing requirement.

5. Wire Gauge and Material

Wire gauge, conductor material, insulation and jacket material can be selected according to current load, flexibility, temperature, bending and environmental requirements.

6. End Termination

The opposite end can be stripped, tinned, crimped with terminals, soldered, connected to a PCB connector or assembled with another plug/socket.

7. Mechanical Protection

For applications with frequent plugging, bending or movement, overmolding, strain relief, heat shrink tubing, grommets or reinforced boots can be added.

8. Testing Requirement

Continuity, polarity, insulation resistance, withstand voltage, pull force and other tests can be performed according to your quality standard.

Send us your drawing, sample or specification for a fast quotation

Manufacturing Capability

As a professional cable assembly manufacturer and wiring harness factory, Yihetai provides complete in-house production for DC plug socket cable assemblies, including wire cutting, stripping, terminal crimping, soldering, injection molding, and final assembly.

Our advanced equipment and experienced team ensure stable quality and efficient production for both low-volume and mass production orders.

From material selection to final assembly and testing, all production processes are carried out under strict quality control to ensure consistent product performance and delivery reliability.

Typical lead time for prototypes is 5-7 days, and mass production within 3-4 weeks.

Quality Inspection for DC Plug & Socket Cable Assemblies

Built for Stable Power Delivery and Long-Term Reliability

A low-quality DC cable can cause voltage drop, unstable power, overheating, intermittent connection, poor contact, or premature failure at the connector end. Yihetai focuses on the key quality points that matter in real applications:

Correct DC plug inner/outer diameter
Stable contact resistance
Correct polarity
Suitable conductor size for current load
Reliable soldering or crimping
Strong cable retention and strain relief
Consistent overmold appearance
Proper insulation and jacket material
Clear labeling and traceability
100% electrical testing before shipment

Engineering Support for Your Custom DC Cable Project

Our engineering team helps customers turn rough ideas, drawings, samples, or application requirements into reliable DC plug and socket cable assemblies. If you are unsure about plug size, wire gauge, current rating, polarity, jacket material, or overmolding structure, we can review your application and recommend a practical manufacturing solution.

We can support:

DC plug and socket matching
Wire gauge and conductor selection
Polarity and pinout confirmation
Overmolded strain relief design
Material selection for flexibility, temperature, moisture, and durability
Prototype sample development before mass production
Continuity, polarity, insulation, and appearance testing

With in-house wire processing, assembly, injection molding, and testing capabilities, Yihetai helps reduce design risk and speed up your custom cable project from sample to production.

Why Choose Yihetai

25+ years in custom wire harness and cable assembly manufacturing

UL, ISO 9001, IATF 16949 certified for global compliance

Full in-house DC connector processing and assembly lines

Expert OEM/ODM for DC power solutions worldwide

Flexible MOQs and rapid prototyping turnaround

Strong engineering team for custom design and connector matching

Frequently Asked Questions

Can you customize DC plug socket cable assemblies according to our drawing or sample?

Yes. We can produce according to drawings, samples, BOM lists, or application requirements, including size, wire gauge, length, structure, and packaging.

What DC plug sizes can you support?

Common options include 5.5 x 2.1 mm and 5.5 x 2.5 mm, and other sizes can be evaluated based on your project requirements.

Can you make panel-mount or overmolded DC socket cable assemblies?

Yes. We can support straight, panel-mount, protected, and overmolded structures depending on your installation and durability requirements.

What information do you need for quotation?

Please send connector size, cable length, wire gauge, current requirement, application environment, quantity, and drawings or photos if available.

Do you support both small trial orders and volume production?

Yes. Yihetai’s public materials position the company as a custom wire harness and cable assembly manufacturer serving OEM projects across industries, with support spanning development, production, testing, and delivery.

Can the polarity be customized?

Yes. We can manufacture center-positive, center-negative, or special wiring polarity according to your drawing or sample. Polarity testing can be included during production inspection.

Can Yihetai customize 5.5×2.1mm DC plug and socket cable assemblies?

Yes. Yihetai can manufacture custom 5.5×2.1mm DC plug and socket cable assemblies, including male-to-female extension cables, DC plug to open-end wires, DC socket cable assemblies, and DC plug cables with additional connectors.

Can you make both male and female DC cable assemblies?

Yes. We manufacture DC male plug cables, DC female socket cables, male-to-female extension cables, panel-mount DC socket harnesses and multi-branch DC power cable assemblies.

Need a Custom DC Plug & Socket Cable Assembly?

Whether you need a simple DC power cable, a molded DC plug assembly, a panel-mount DC socket harness or a fully customized cable solution, Yihetai can help you develop a reliable and cost-effective product for your application.