DC Power Cable Manufacturer – Custom DC Cords for LED, CCTV & Industrial Equipment

Industrial-grade DC power cables engineered for reliable performance in LED lighting, security systems, and automation equipment.
Custom voltages, connectors, and specifications to match your exact requirements

✔ 10+ Years Manufacturing          ✔ CE RoHS Certified          ✔ OEM ODM Supported

Bulk Pricing Table

Order QuantityUnit Price ReferenceCustomization OptionsDelivery Time
100 – 499 pcs$1.20 – $1.50Standard Packaging5-7 days
500 – 999 pcs$0.95 – $1.20Logo Printing Available7-10 days
1000 – 4999 pcs$0.75 – $0.95OEM Packaging10-15 days
5000+ pcsBest Factory PriceOEM / ODM15-25 days
* Final price depends on cable specifications, length, and raw material costs

DC Power Cable Specifications We Manufacture

5.5×2.1 mm Universal Standard
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5.5×2.1 mm
Universal Standard
The most widely used DC barrel size, compatible with LED lighting CCTV security networking equipment. Available in straight / 90° angled versions, wire gauges 18AWG / 20AWG / 22AWG to meet 1A–5A current requirements.
Length 0.3–10m Overmolded strain relief Pure copper conductor Flex‑resistant design
  • Supports custom dual‑end configurations, shielded or unshielded
  • Gold‑plated terminals optional for lower contact resistance
  • Black / white jacket for minimalist integration
✓ 5.5×2.1mm straight plugs in stock, angled versions lead time 3–5 days
5.5×2.5 mm High-Power Industrial
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5.5×2.5 mm
High‑Power Industrial
Engineered for industrial monitors, professional audio and high‑power LED drivers. The 2.5mm inner diameter provides larger contact area, increasing current capacity by 30%. Choose 16AWG–18AWG heavy‑duty wire, rated up to 105°C.
Current rating 5A–8A Reinforced metal connector Double‑insulated jacket 5000+ cycle pull resistance
  • Compatible with 2.1mm female sockets (partial spring‑contact design)
  • Industrial‑grade flame‑retardant PVC / silicone jacket options
  • Heat‑shrink sealing available for moisture protection
⚡ High‑current versions come standard with tinned copper braid shielding for enhanced EMI rejection
3.5×1.35 / 4.0×1.7 Compact Device Series
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3.5×1.35 / 4.0×1.7
Compact Device Series
Widely used in portable routers, tablets, smart home gateways and miniature embedded boards. Precision molds ensure stable insertion force; flexible cable resists bending, perfect for tight internal routing.
24AWG~28AWG Ultra‑flexible fine wire Anti‑oxidized copper shell Two‑color polarity marking
  • Customizable with different plug types on each end (adapters / conversion cables)
  • Reinforced strain relief, >8000 cycles flex life
  • Extended lengths 1.5m–5m, no signal degradation
★ Commonly used for Raspberry Pi, set‑top boxes and dome camera power
90° Right-Angle Space-Saving Choice
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90° Right‑Angle
Space‑Saving Choice
Ideal for wall‑mount equipment, cabinet wiring and security cameras in tight corners. Four exit directions (up/down/left/right) reduce connector height by up to 60% for flush mounting.
5.5×2.1/2.5mm 3.5×1.35mm optional Straight + angled hybrid Fully overmolded
  • Reinforced SR tail prevents cable breakage at bend point
  • Passes 10,000‑cycle flex test
  • Compatible with most power adapters and end devices
↺ Bulk orders can include special angles (60° / 120° upon request)
Male-to-Female Extension Adapter Reach Solution
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Male‑to‑Female Extension
Adapter Reach Solution
Effortlessly extend the distance of your power adapter, avoiding blocked outlets or short cables. Preferred for security installations, LED signage and server racks. Precision‑matched plug and socket, engineered for minimal voltage drop.
Length 0.5m–15m 18AWG/20AWG/22AWG Dust‑cap for female end Pure copper tinned terminals
  • All common sizes: 5.5×2.1 / 2.5 / 4.0×1.7 / 3.5×1.35
  • Voltage drop calculations available; 16AWG recommended for long runs
  • Optional LED indicator versions
🔌 Rack‑mount friendly, also available with L‑shaped female sockets and panel‑mount styles
DC to Bare Wire Ends Terminal Block / PCB Ready
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DC to Bare Wire Ends
Terminal Block / PCB Ready
DC barrel on one end, stripped and tinned leads on the other — ideal for terminal blocks, PCB soldering, DIY modifications and prototyping. Standard red/black wire polarity identification; custom jacket colors and high‑temperature silicone available.
Strip length 5–12mm Even tin coating for easy soldering Multiple plug sizes Flame‑retardant PVC / silicone
  • UL1007, UL2468 certified electronic wire options
  • OEM labeling and custom heat‑shrink color rings accepted
  • Available un‑stripped for secondary processing
✚ Suitable for battery packs, industrial controllers, small solar systems

Why Choose Our DC Power Cables?

Au/Ni

Precision Barrel Connectors

Our DC power plugs feature precision-molded connectors with tight tolerances for secure fit and reliable contact. Gold-plated or nickel-plated options available for corrosion resistance and improved conductivity. No loose connections, no power interruptions.

⭐ Gold-plated contacts · Low impedance 🔩 Precision overmolded shell
18AWG 20AWG 22AWG Low V-drop

Correct Wire Gauge for Your Current

We use the appropriate AWG wire gauge based on your current requirements. Thicker copper conductors minimize voltage drop over longer distances, ensuring your devices receive proper power.

🔹 18AWG → up to 5A 🔸 20AWG → up to 3A 🔹 22AWG → up to 2A

✔ High-purity oxygen-free copper, stable transmission over long distances, minimal power loss.

⤹ 5000+ flex cycles

Durable Strain Relief

Reinforced strain relief at both connector ends prevents wire breakage from bending and pulling. Tested for thousands of flex cycles. Ideal for applications where cables are frequently moved or installed in challenging environments.

🛡️ Dual strain relief 🔄 10k+ flex cycle test

✔ Preferred for industrial robotics, medical equipment, automotive power, and harsh environments.

Pantone® LOGO shrink tube / custom mold

Custom Length, Color & Branding

Need a specific length? We cut to your exact requirements. Custom jacket colors available (Pantone matching). Add your logo with heat-shrink tubing, cable tags, or custom connector molding for brand identity.

🎨 Pantone® color matching 📏 0.15m ~ 30m precision cut 🏷️ Laser marking / heat-shrink logo 🔌 Custom connector overmolding

End-to-end branding solutions — make your cable part of your product identity.

Why Choose Us

16 Years Experience

🏭 Direct Factory5

10+ years USB cable manufacturing experience with stable production capacity.

usb Certified Quality

📜 Certified Quality

Products comply with CE, RoHS, REACH and international standards.

usb Fast Sampling

⚡ Fast Sampling

Sample orders ready within 3-5 working days.

🎨 OEM ODM Service

Logo printing, custom colors and packaging supported.

🚚 Stable Delivery

Strong supply chain ensures reliable delivery schedule.

Customer Service Fast Response

💬 Fast Response

Professional sales team responds within 24 hours.

Technical Specifications

ParameterSpecification Options
Connector Types5.5×2.1mm / 5.5×2.5mm / 4.0×1.7mm / 3.5×1.35mm / 2.5×0.7mm / Custom
Connector StyleStraight / Right-Angle (90°) / Panel Mount
GenderMale / Female / Male to Female Extension
Wire Gauge (AWG)18AWG / 20AWG / 22AWG / 24AWG / 16AWG (Heavy Duty)
Conductor MaterialTinned Copper / Bare Copper
Jacket MaterialPVC / TPE / Rubber / PU (Oil-resistant) / LSZH (Low Smoke)
Jacket ColorBlack / White / Custom (Pantone)
ShieldingUnshielded / Foil Shielded / Braided Shield
Length Options30cm / 50cm / 1m / 1.5m / 2m / 3m / 5m / 10m / Custom
Termination OptionsDC Plug / Bare Wire / Tinned Ends / Terminal Blocks / Custom
Voltage RatingUp to 300V (Depending on cable construction)
Current Rating1A / 2A / 3A / 5A / 10A+ (Based on AWG)
CertificationsCE, RoHS, REACH, UL (Optional)

Common Applications for DC Power Cables

LED Strip Lighting

DC power cables are essential for LED strip installations. Our 5.5×2.1mm and 5.5×2.5mm cables connect LED drivers to strips, available in various lengths for residential and commercial lighting projects.

CCTV Cameras & Security Systems

Security cameras commonly use DC barrel connectors for power. Our right-angle cables are perfect for dome cameras and tight installations. Extension cables available for long-distance runs.

Routers & Networking Equipment

Many routers, switches, and modems use 5.5×2.1mm or smaller barrel connectors. Custom length cables help organize networking racks and eliminate excess cable clutter.

Industrial Control Panels

Industrial equipment often requires custom DC power connections. We manufacture cables with specific lengths, gauges, and terminations for PLCs, sensors, and control systems.

Medical Devices

Medical instruments require reliable power delivery. Our DC cables can be manufactured with medical-grade materials and certifications upon request.

Consumer Electronics

From monitors to speakers, portable devices to home appliances, we supply custom DC power cords for a wide range of consumer products.

Complete DC Power Cable Customization

Connector Size & Type

Choose from standard sizes or submit custom dimensions to fit various power interfaces.
5.5x2.1mm 5.5x2.5mm 4.0x1.7mm 3.5x1.35mm Custom dimensions
  • Straight
  • Right-angle
  • Panel-mount
Non-standard sizes, threaded locking, or special pin configurations are available — contact our engineering team for drawing review.

Wire Gauge & Conductor

Flexibly select wire gauge and conductor material based on current load and transmission distance.
16AWG 18AWG 20AWG 22AWG 24AWG
  • Tinned copper — Superior corrosion resistance, ideal for humid/outdoor environments
  • Bare copper — Maximum conductivity, lowest impedance
Multi-conductor, shielded, or twisted pair configurations supported to meet high-current or signal transmission needs.

Jacket Material & Color

Jacket material determines durability, flexibility, and environmental adaptability; color can match any brand identity.
PVC (General use) TPE (Eco-friendly) Rubber (Flexibility) PU (Oil resistance) LSZH (Low-smoke)
Any Pantone color — match device aesthetics, wiring identification, or brand colors
Flame rating, UV resistance, oil resistance, high-temperature compounds, and other specialty materials available.

Termination Options

Termination styles determine connection reliability and installation convenience, adaptable to various device interfaces.
  • Standard DC plug
  • Bare wire
  • Tinned ends
  • Terminal blocks
  • Custom connectors
Your choice — full range of aviation plugs, waterproof connectors, M-series, etc., integrated on demand.

Branding & Packaging

Enhance brand recognition with professional packaging options for single units to bulk deliveries.
  • Custom labels
  • Heat-shrink tubing with logo
  • Custom connector molding
📦 Bulk packaging 🛍️ Poly bags 🎁 Retail-ready packaging
Product leaflets, hang tags, QR code labels, mixed packing, and serial number management available.

Frequently Asked Questions About DC Power Cables

Q. What is the difference between 5.5x2.1mm and 5.5x2.5mm DC connectors?
A. Both have the same outer diameter (5.5mm), but the inner pin diameter differs: 2.1mm vs 2.5mm. They are not interchangeable - using the wrong size can cause poor contact or damage. Check your device's required size before ordering. Many devices have the size printed near the power port.
Q. What wire gauge (AWG) do I need for my DC power cable?
A. Wire gauge depends on current (amps) and cable length. As a general guide: 22AWG supports up to 2A, 20AWG up to 3A, 18AWG up to 5A, and 16AWG up to 10A. For longer runs, you may need thicker wire to prevent voltage drop. Contact us with your requirements and we'll recommend the appropriate gauge.
Q. Do you offer right-angle DC power cables?
A. Yes, we manufacture right-angle (90-degree) DC power cables in all standard sizes. These are ideal for tight spaces, wall-mounted devices, and installations where a straight plug would protrude too far. Available in up, down, left, and right orientations.
Q. What is the maximum length for DC power cables?
A. Maximum practical length depends on voltage and current. For 12V/1A applications, lengths up to 10m are possible with proper wire gauge. For higher currents, shorter lengths are recommended to minimize voltage drop. We can calculate the optimal gauge for your specific length requirements.
Q. Can you make DC extension cables (male to female)?
A. Yes, we manufacture male to female DC extension cables in all standard sizes. These allow you to extend the reach of your existing power supply. Custom lengths available.
Q. What is the MOQ for custom DC power cables?
A. Standard MOQ is 1000 pieces per design. For startups and small projects, we offer low MOQ options - please contact us to discuss your specific needs.
Q. Can I get a sample before mass production?
A. Yes, samples are available within 7-10 days. Sample costs are typically deducted from your mass production order. Custom samples based on your specifications are also available.
Q. Do you offer DC power cables with bare wire ends?
A. Yes, we offer DC plug to bare wire (stripped and tinned) cables. This is popular for custom installations, connecting to terminal blocks, or DIY projects. Wire colors are typically red (positive) and black (negative).
Q. What certifications do your DC power cables have?
A. Our standard DC cables are CE, RoHS, and REACH compliant. UL certification is available upon request for specific applications and volumes.
Q. Can you match a specific color for my DC cable?
A. Absolutely. We offer Pantone color matching for cable jackets and connector housings. Send us your brand colors and we'll match them exactly.

Certifications

EU CE certification mark
US FCC certification mark
EU Directive on Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment

We create lasting value for our customers and partners with the Corporate Governance system. We actively seek and apply the highest global standards as the basis for all our decision-making and control processes.

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