Custom DC Power Cable Assembly Manufacturer

Yihetai is a professional custom DC power cable assembly manufacturer in China. We provide customized DC power cable assembly solutions as a trusted cable assembly supplier for reliable low-voltage power delivery in diverse applications. As a wire harness manufacturer and custom wire harness provider, we customize wire gauge, cable length, DC connectors like barrel jacks or XT60, terminals, insulation, shielding, overmolding, and colors from your drawings or samples. Our OEM wire harness and custom wiring solutions power industrial machinery, consumer gadgets, automotive accessories, solar setups, medical tools, and telecom gear.

If you are looking for a dependable wiring harness factory or OEM wire harness supplier for DC power connection products, Yihetai is ready to support your project with fast evaluation, engineering feedback and quotation.

What Is DC Power Cable Assembly?

DC power cable assembly is a customized cable or wire assembly used for transmitting direct current (DC) power safely and efficiently from sources to devices. It combines power wires with polarity-specific connectors to handle voltages from 5V to 48V and currents up to 100A. It usually includes a DC plug, DC socket, bare wire end, terminal, molded connector, or other customized interface combined with suitable conductors and insulation materials. Depending on the application, it can be designed for power input, extension, split power distribution, panel mounting, or connection between internal modules.

Compared with standard off-the-shelf cables, custom DC power cable assemblies can better match the equipment structure, current requirement, plug specification, environmental condition, and installation route. This improves assembly efficiency, reduces connection errors, and helps ensure stable electrical performance in the final product.

Common Custom DC Power Cable Assembly Types We Manufacture

Yihetai can manufacture a wide range of custom DC power cable assemblies according to customer drawings, samples, and application requirements, including:

Barrel jack (2.1mm/2.5mm/5.5mm) power assemblies for electronics
DC terminal block to jack cables for control panels
Multi-conductor DC power harnesses for LED strips
High-current DC assemblies (up to 20A) for industrial motors
DC to USB adapter cable assemblies for charging
XT60/XT90 high-current for drones and RC
Pigtail leads with tinned ends for PCBs
DC plug to JST connector cable assembly
DC plug to Molex connector cable assembly
DC male to DC female extension cable
Right angle DC power cable assembly
DC plug and socket cable assembly
DC plug to open wire cable assembly
DC plug to DC jack extension cable
Male to female DC power extension cable
Right-angle DC power cable assembly
Panel mount DC power cable assembly
Y-splitter and multi-branch DC power cable
Fused DC power cable assembly
DC power cable with terminal, ferrule, or ring terminal end
DC power harness for LED lighting systems
DC power cable for CCTV, routers, control boxes, and small appliances

Key Features of our DC Power Cable Assembly

Key Features of our DC Power Cable Assembly
Tailored lengths 10cm-50m with custom polarity coding
Supports barrel jacks (2.1/2.5/5.5mm), terminals, XT60,Powerpole, Tamiya connectors
Gauges 16-28 AWG for currents up to 20A continuous
Efficient power delivery with low-voltage drop designs
Crimping, soldering, welding for vibration-resistant joints
Rated for -40°C to 125°C in harsh industrial settings.
Full electrical testing including load and insulation checks

Technical Specifications

Parameter	Specification
Product Name	DC Power Cable Assembly
Wire Gauge	16 AWG – 28 AWG, customizable
Cable Type	Single core, twin core, multi-core, shielded or unshielded
Connector Type	DC plug, DC jack, male/female barrel connector, Barrel (2.1/2.5/3.5mm), XT60/90, Anderson，open wire end, terminal end，screw terminal
Common Plug Sizes	3.5 x 1.35 mm, 5.5 x 2.1 mm, 5.5 x 2.5 mm, customizable
Connector Style	Straight, right-angle, panel mount, splitter, molded
Conductor Material	Bare copper, tinned copper
Jacket Material	PVC, TPE, TPU, silicone, customized
Temperature Range	-40°C to +105°C, depending on material selection
Voltage Rating	Customized according to application requirement
Current Rating	Customized according to conductor size and connector type
Shielding	Optional foil shielding, braid shielding, or unshielded
Color	Black, white, red, or customized
Testing	Continuity test, polarity check, insulation test, high-voltage test, visual inspection

Applications

Our DC power cable assembly solutions are widely used in:

Industrial automation equipment
Control panels and PLC systems
DC-powered monitors and HMI terminals
Barcode scanners and smart terminals
Router and communication device power connection
Test and measurement equipment
Security control units
Embedded electronic modules and control boards
LED lighting systems
CCTV cameras and surveillance accessories
Equipment requiring right-angle or panel-mount power entry solutions

Home routers and networking devices
Consumer electronic products
Smart home devices
Home appliances
Display equipment and adapters
Portable low-voltage power devices
Automotive electronic accessories
Specialized medical peripheral devices
Power adapter harnesses for OEM equipment
Battery-powered portable instruments
Custom device interfaces requiring DC plug to board or terminal connection

Customization Options

At Yihetai, all DC power cable assembly products can be customized according to customer requirements.

Item	Options Available	Notes
Wire Type	UL wire, DC power cable, shielded wire, flat wire, multi-core cable	Selected by current, flexibility, and environment
Conductor	Bare copper, tinned copper, stranded conductor	Chosen by conductivity and durability needs
Wire Gauge	18 AWG – 26 AWG or custom	Based on current load and voltage drop
Length	50 mm to 10 m+	Customized per installation layout
Color	Black, white, red, yellow, customized	Supports easy identification
Connector	DC plug, DC jack, barrel plug, panel mount, right-angle，Barrel jack, XT60, Anderson, spade terminals	Common sizes and custom mating types available
Terminal	Open end, tinned end, ferrule, ring terminal, spade terminal	For direct power input or control box connection
Jacket Material	PVC, TPE, TPU, silicone	For flexibility, heat resistance, or outdoor use
Process	Cutting, stripping, soldering, crimping, overmolding, bundling	In-house manufacturing support
Testing	Continuity, polarity, high-voltage, insulation, visual inspection	100% test can be arranged

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

Yihetai has integrated manufacturing capability covering wire production, wire processing, terminal crimping, soldering, injection molding, assembly, and testing. Your company profile shows dedicated production sites for cable wire and wire harness manufacturing, with in-house equipment such as extrusion machines, semi-automatic terminal machines, computer cutting machines, automatic terminal machines, welding machines, injection molding equipment, and testing devices. This supports stable quality control and flexible customization for DC power cable assembly projects.

For DC power cable assembly, we can support sample development, connector matching, wire selection, small-batch trial orders, and mass production. 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. Yihetai’s profile also states production capability in wire processing and shows factory testing and inspection areas, which helps buyers trust delivery capacity.

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

Quality Assurance & Control

Yihetai maintains rigorous full-process quality control through documented systems, integrating SPC tools and operator training to uphold standards from procurement to dispatch for DC power cable assemblies. Certified to ISO 9001:2015, UL, and IATF 16949, we meet global benchmarks for power electronics and automotive power delivery.

Typical inspection items for DC power cable assembly include:

Incoming material inspection
Wire and connector specification verification
Terminal crimp pull test
Soldering quality inspection
Polarity verification
Visual and continuity verification on 100% units
High-voltage test when required
Dimensional and fixture inspection
Full-load thermal rise and voltage drop tests
Final appearance and packaging inspection
Every harness is delivered with guaranteed electrical integrity and consistent quality across batches

Why Choose Yihetai

Over 25 years of experience in wire harness and cable assembly manufacturing, helping reduce communication costs and project risks for OEM buyers

Strong engineering support for custom design and connector matching, with senior engineers providing fast response and reliable technical solutions

In-house production and testing ensure better control over key manufacturing and inspection processes for consistent quality and reliability

Flexible support from prototype to mass production, suitable for new product development, pilot runs, and long-term supply

Certified quality systems and full testing ensure reliability, supported by ISO 9001:2015, UL, and IATF 16949

Proven experience across diverse industries, including industrial, automotive, communication, medical, home appliances, renewable energy, and consumer electronics

Frequently Asked Questions

What wire gauge should I choose for my DC power cable assembly?

Wire gauge depends on current, length, and allowable voltage drop (typically <3%). For 12V/10A over 2m, use AWG 14; For 48V/50A solar, AWG 6 we calculate precisely using NEC ampacity tables and your specs, factoring insulation temp rating (90°C+). Provide voltage/current/length for free recommendation and prototype. Silicone wires handle heat better for compact installs.

Can your DC power cable assemblies handle high currents like 100A?

Yes, we build up to 200A with thick AWG 4/2/0 or parallel conductors, using Anderson SBS50+ or lugs. Rated for continuous duty at 60°C rise, with thermal imaging verification. Ideal for EV chargers, inverters. Vibration-proof crimps and XLPE insulation ensure longevity. UL1015 compliant; send power budget for optimized design.

What is the lead time and MOQ for custom DC power cable assembly?

Samples/prototypes: 5-7 days, no MOQ request; Production: 3-4 weeks for 1k+ pcs, scalable to millions. Tiered pricing drops 20% at volume. We stock common connectors for speed ERP tracks orders.

Do you offer waterproof DC power cable assemblies?

Definitely, IP67/IP68 with molded glands, potting, or heat-shrink. Silicone/PU jackets for submersion up to 1m. Perfect for marine solar, outdoor LEDs. We test submersion and pressure; compatible with PG/M glands. Specify ingress level for matching.

What testing do you perform on DC power cable assemblies?

Comprehensive: Hi-Pot (2kV), insulation resistance (>100MΩ), crimp pull (per IPC-620), continuity (<0.1Ω/m), voltage drop at rated load/heat cycle. Optional salt spray, thermal shock. Full reports with traceability. Ensures zero failures in field for critical apps like medical/solar.

Looking for a reliable DC power cable assembly manufacturer?

Send us your drawing, sample, or technical requirements, and our team will provide a customized wire harness or cable assembly solution for your project