Custom DC Plug Socket Cable Assembly Manufacturer

Yihetai is a professional custom DC plug socket cable assembly manufacturer and reliable cable assembly supplier in China, specializing in high-quality DC power connection solutions. As an experienced wire harness manufacturer and custom cable assembly provider, we deliver tailored DC cable assemblies for stable power transmission across various industries.

Our DC plug and socket cable assemblies are designed for power supply applications, featuring male/female DC connectors with secure connections and excellent electrical performance. Based on customer drawings or samples, we can customize wire gauge, cable length, connector size (5.5×2.1mm, 5.5×2.5mm, etc.), terminal type, insulation materials, overmolding structures, and cable colors.

As a trusted wiring harness factory and OEM wire harness partner, we provide flexible custom wiring solutions for industrial equipment, LED lighting, consumer electronics, security systems, and renewable energy devices.

What Is DC Plug Socket Cable Assembly?

DC plug socket cable assembly is a customized cable solution used for low-voltage DC power transmission. It typically consists of a DC male plug and a DC female socket connected by a cable, allowing power to be transmitted between devices such as adapters, batteries, and electronic equipment.

Compared with standard DC cables, custom cable assemblies provide better compatibility, improved durability, and optimized installation. They are widely used in applications requiring stable and secure DC power connections.

In many industries, DC cable assemblies are not just basic cords. They may need to integrate with terminals, JST connectors, PCB headers, waterproof connectors or molded housings. That is why many customers prefer working with a professional custom cable assembly manufacturer instead of buying off-the-shelf parts that do not fully match the application.

Common Custom DC Plug Socket Cable Assembly Types We Manufacture

At Yihetai, we can manufacture different types of custom DC plug socket cable assemblies based on your application, installation space and electrical requirements, including:

DC male plug to open wire cable assembly
DC female socket to open wire cable assembly
DC male to female extension cable assembly
Panel-mount DC socket cable assembly
DC plug splitter cable assembly
DC Y splitter cable assembly
Right-angle DC plug cable assembly
Overmolded DC plug and socket cable assembly
Waterproof DC power cable assembly
DC power cable with terminal, tinned end, or board connection
Custom hybrid cable combining DC power and signal lines
Panel-mount DC socket harnesses with flying leads
OEM internal wiring harness with DC plug socket interface

We also provide integrated designs combining DC power with signal cables as part of complete OEM wire harness solutions.

Key Features of our Our DC Plug Socket Cable Assembly

Compatible with standard 2.1/2.5/3.0mm barrel sizes, center-positive/negative
18-28 AWG wires in PVC/TPE for 1A-30A currents
Low resistance for efficient DC power up to 48V without drop
Optional IP67 waterproofing and locking mechanisms
Rated -40°C to +105°C for harsh environments
Custom cable lengths, plug sizes and wire configurations for OEM and replacement applications
Available with straight, right-angle, panel mount and overmolded DC connector structures
Suitable for low-voltage power transmission in compact or space-limited equipment
Multiple wire gauges and jacket materials available for flexibility and durability needs
Optional Y split, branch, fuse, terminal and hybrid connector designs
Stable power connection with reliable crimping, soldering and assembly process
100% electrical testing before shipment for continuity and connection reliability

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

Applications

Our DC plug socket cable assembly solutions are widely used in:

Industrial automation equipment
Control panels and power distribution boxes
PLC auxiliary power connection
Small machines and embedded control systems
HMI panels and instrumentation devices
Factory monitoring and communication equipment
LED lighting systems and LED strip power leads
CCTV cameras and security devices
Routers, set-top boxes, and low-voltage communication products

Home appliances and small electronic devices
Battery chargers, adapters, and consumer power accessories
Smart home devices and electronic modules
Medical auxiliary electronic devices
Renewable energy monitoring accessories
Automotive auxiliary low-voltage systems
Portable devices and test equipment
Outdoor equipment with protected or waterproof DC socket designs
OEM equipment requiring customized power input/output harnesses

Customization Options

At Yihetai, all DC Plug Socket Cable Assembly products can be customized according to customer requirements.

Custom Item	Available Options	Notes
Wire Type	DC power cable, extension cable, pigtail cable, hybrid cable	Chosen by installation and current requirement
Conductor	Bare copper, tinned copper	Selected by conductivity and environment
Wire Gauge	18–24 AWG typical or custom	Determined by current load and cable length
Length	Fully customized	Short internal leads to long extension cables
Color	Black, red/black, white, custom	Supports identification and branding
Connector	DC male plug, DC female socket, panel mount jack, custom ends	5.5 x 2.1 mm / 5.5 x 2.5 mm and other options
Terminal	Stripped/tinned end, crimp terminal, soldered end, custom interface	Based on assembly method
Jacket Material	PVC, TPE, PUR, LSZH, custom	Depends on flexibility and environment
Process	Cutting, stripping, soldering, crimping, overmolding, panel assembly, labeling	Selected by design
Testing	Continuity, polarity, open/short, hi-pot, visual, dimensional	Inspection plan can be customized

We can manufacture based on customer drawings, samples, BOM lists or application requirements.

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 Assurance & Control

Full-process quality control at Yihetai uses documented systems to inspect every stage, ensuring defect-free DC plug socket cable assemblies from raw wire to packed product. Certified with ISO 9001:2015, UL, and IATF 16949 for automotive standards in our cable assembly supplier operations.

Typical inspection items for DC plug socket cable assembly include:

Incoming material inspection for conductor purity
Terminal crimp/solder pull test (min 50N)
Visual and continuity verification
High-voltage dielectric test (up to 1500V)
Dimensional check for plug/socket fit
Insulation resistance (100MΩ min)
Every harness is delivered with guaranteed electrical integrity and consistent quality across batches.

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.

Looking for a reliable DC Plug Socket Cable Assembly manufacturer?

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