Custom USB Cable Assembly Manufacturer

Yihetai is a professional USB cable assembly manufacturer and custom cable assembly supplier in China, specializing in high-quality, reliable, and fully customized connectivity solutions. With over 23 years of experience in the wire harness industry, we provide custom USB cable assembly, custom wire harness, and OEM wire harness solutions for a wide range of power, signal transmission, and data communication applications.

Based on customer drawings, samples, or technical requirements, we can customize USB cable assemblies in terms of wire gauge, cable length, connector types (USB-A, USB-B, USB-C, Micro USB, Mini USB), shielding structure, overmolding, insulation materials, and color. Our solutions are widely used in industrial electronics, consumer devices, automotive systems, medical equipment, and smart devices.

Our USB cable assemblies are widely used in industrial equipment, consumer electronics, medical devices, automotive systems, communication equipment, and smart devices. Whether you need prototypes or mass production, Yihetai provides flexible and cost-effective custom wiring solutions.

Looking for a reliable cable assembly manufacturer? Contact us today for your custom USB cable assembly project.

What Is USB Cable Assembly?

A USB cable assembly is a customized cable solution used to transmit power, data, or both between devices, modules, control boards, and external interfaces. It can be configured with different USB connector standards such as USB-A, USB-B, Mini USB, Micro USB, or USB Type-C, and combined with terminals, board connectors, female sockets, panel mount structures, or other customized ends.

Compared with standard off-the-shelf USB cables, a custom USB cable assembly is designed to match the actual installation space, electrical requirements, connector layout, and working environment of the final equipment. It can reduce assembly difficulty, improve wiring reliability, support compact product design, and help OEM manufacturers achieve cleaner and more stable connections.

For many buyers and engineers, the real value of a custom USB cable assembly is not only in the connector itself, but in the complete integration of wire structure, shielding, molding, strain relief, branch design, and termination method. This is especially important in industrial electronics, embedded devices, portable equipment, medical systems, and smart products.

Common Custom USB Cable Assembly Types We Manufacture

Yihetai can manufacture different styles of custom USB cable assemblies according to project requirements, including:

USB-A to board connector cable assemblies
USB-A to terminal or JST connector cable assemblies
USB-A to Micro USB cable assemblies
USB-A to Mini USB cable assemblies
USB-A to USB-B cable assemblies
USB-A to USB Type-C cable assemblies
USB Type-C to board-level custom cable assemblies
USB female socket cable assemblies
Panel mount USB extension cable assemblies
Right-angle USB cable assemblies
Overmolded USB cable assemblies
USB power and signal combined cable assemblies
USB 2.0, 3.0, and USB4 high-speed variants cable assemblies
USB Type-A to Type-A extension assemblies for peripherals

These assemblies can be designed for charging only, data transfer only, or hybrid power and signal applications depending on your device architecture.

Key Features of Our USB Cable Assembly

Custom cable lengths, wire structures and branch designs for different installation spaces
Compatible with USB Type-A, B, C, Micro, Mini from brands like Molex, JST
Compatible with USB-A, USB-B, Mini USB, Micro USB, Type-C and customized terminal ends
Available with shielded or unshielded cable constructions for data and power transmission needs
Optional overmolding and strain relief for improved durability and repeated bending resistance
Flexible customization of conductor size, insulation material, jacket color and cable appearance
Stable high-speed data up to USB 3.1 with foil/braid shielding
Stable assembly quality through crimping, soldering, molding and final electrical testing
100% testing before shipment to improve consistency and reduce assembly risk

Technical Specifications

Item	Specification
Product Name	Custom USB Cable Assembly
USB Interface	USB-A, USB-B, Mini USB, Micro USB, USB Type-C
Cable Type	USB 2.0 cable, USB 3.0 cable, panel mount cable, pigtail cable, hybrid cable
Wire Gauge	18–32 AWG, customizable
Conductor Material	Bare copper, tinned copper, silver-plated copper, as required
Connector Type	Standard USB connectors, JST, Molex, TE, Hirose, Dupont, or custom connectors
Cable Length	Custom length according to drawing or application
Jacket Material	PVC, TPE, PE, PP, TPU or specified material
Shielding	Unshielded, foil shield, braided shield, or hybrid shielding
Overmolding	Optional
Color	Black, white, gray, red or customized
Temperature Range	Typically -20°C to +80°C, higher on request
Voltage Rating	For low-voltage power and signal applications, design-specific
Testing	Continuity, insulation resistance, Hi-Pot, visual inspection, dimensional inspection, functional testing

Applications

Our USB cable assembly solutions are widely used in:

Industrial automation equipment
Control panels and PLC interface systems
HMI terminals and embedded control modules
Barcode scanners and handheld data terminals
Thermal printers and label printing systems
Machine vision accessories and peripheral devices
Test and measurement equipment
Smart vending, POS and kiosk devices
Consumer electronics
USB charging and data transfer accessories

Smart home devices and IoT gateways
Computer peripherals and docking products
Home appliances with control boards
Display, communication and multimedia devices
Medical monitoring and portable diagnostic devices
Specialized electronic instruments
Customized portable equipment
Integrated device harnesses requiring USB interface connection
Equipment requiring panel mount or secure internal USB wiring
Compact devices that need customized USB to board or USB to terminal connection

Customization Options

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

Item	Available Options	Notes
Wire Type	USB 2.0, USB 3.0, multi-core cable, shielded cable, hybrid cable	Based on power, data, or signal requirement
Conductor	Bare copper, tinned copper, silver-plated copper	Selected by performance and budget
Wire Gauge	18–32 AWG or custom	Depends on current, signal, and cable structure
Length	Fully customized	According to drawing or installation space
Color	Black, white, gray, red, blue or custom	For product matching or identification
Connector	USB-A, USB-B, Mini USB, Micro USB, USB-C, custom mating connector	Brand and pitch can be specified
Terminal / End Type	Open wire, tinning, ferrule, ring terminal, board connector, custom end	Suitable for integrated assembly
Jacket Material	PVC, TPE, TPU, PE, PP	Chosen by flexibility, durability, and environment
Shielding	None, foil, braid, ferrite	Optional for EMI control and signal stability
Process	Crimping, soldering, overmolding, ultrasonic welding, bundling	Depends on design structure
Marking / Labeling	Heat shrink label, print mark, part number label	For identification and traceability
Testing	Continuity, insulation, Hi-Pot, appearance, dimensional, functional	Final test 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 dedicated USB cable assembly manufacturer and cable assembly supplier, Yihetai operates a state-of-the-art wiring harness factory in China with full in-house production. From wire extrusion and cutting to connector assembly, overmolding, and testing, we handle high-volume OEM wire harness orders efficiently. Our custom wiring solution capabilities support prototypes in 5-7 days and mass production in 3-4 weeks, ensuring on-time delivery for global clients.

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

Yihetai implements full-process quality control with documented systems covering incoming inspection, in-process monitoring, and final outgoing checks. Every stage uses automated tools and trained technicians to prevent defects and ensure USB cable assemblies meet specs. We are certified with ISO 9001:2015, UL, and IATF 16949, guaranteeing compliance for automotive and electronics standards..

Inspection items can include:

Incoming material inspection for conductors and connectors
Terminal crimp pull test (up to 50N force)
Visual and continuity check on 100% products
High-voltage test (500V DC)
Dimensional and fixture inspection for tolerances
EMI shielding verification and aging tests
USB data speed and signal integrity verification
Every harness is delivered with guaranteed electrical integrity and consistent quality across batches.

Why Choose Yihetai

With over 25 years of experience in wiring harness and cable assembly manufacturing, we leverage our proven expertise to reduce communication costs and minimize project risks

With a strong engineering team for custom design and connector matching, we support customers in evaluating structure, connection methods, and manufacturability for custom USB cable projects

With in-house processing capabilities covering wire processing, assembly, and testing, we maintain full control over key steps to ensure superior consistency

We offer flexible production from small batches to mass production, supporting prototype validation, pilot runs, and long-term supply programs

With a 100% testing and full traceability approach, every shipment is thoroughly inspected before delivery to ensure enhanced field reliability

Extensive experience across multiple industries, including industrial, automotive, medical, renewable energy, and consumer electronics

Frequently Asked Questions

Can you make custom USB cable assemblies based on our drawing or sample?

Yes. We can manufacture based on drawings, samples, BOM lists, or specific application requirements. This is already part of Yihetai’s standard custom manufacturing approach.

What USB connector types can you support?

We can support USB-A, USB-B, Mini USB, Micro USB, and USB Type-C structures, as well as USB to terminal, USB to board connector, or USB to custom connector combinations. Your own catalog already shows USB 3.0 Cable, USB Cable Assembly, Panel Mount USB Cable, and Micro USB Cable categories.

Can you add shielding, ferrite, or overmolding to improve cable performance?

Yes. Depending on your application, we can provide shielding, ferrite components, strain relief, and overmolded structures to improve durability, signal stability, and installation reliability.

Do you support small trial orders as well as large production orders?

Yes. Yihetai supports both small batches and high-volume production, which is useful for new product development and ongoing supply projects.

What information should we send for quotation?

Please send connector type, cable length, wire specification, function requirement, quantity, drawing, sample photos or BOM list. If available, also include current, data standard, installation environment and testing requirements.

Need a custom USB cable assembly for your application?

Contact Yihetai today for fast support on prototype development, technical evaluation and quotation.