How to Save Money When Buying Customized Computer Connectors and Cables

Apr. 07, 2025

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Fast and Inexpensive Custom USB Cable Assemblies - Epec's Blog

Short for "Universal Serial Bus," a USB cable is one that has become a nearly ubiquitous part of our lives, even if some people don't necessarily realize it. Technologically speaking, it involves an industry standard that created precise specifications for not only how these types of cables can be manufactured, but how they can connect one device to another, how power and data can be transmitted, and more.

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What Types of Products Use USB?

Most consumer electronics still use some variation of the USB protocol. Smartphones, for example, typically come with a USB charging cable, be it traditional USB or micro/mini variants. One notable exception to this is the Apple iPhone, which still uses the company's own lightning cable design. Anytime you need to connect a computer to a peripheral device like a laptop or mouse, it will likely use a USB cable to do so.

The History of USB: Breaking Things Down

The USB 1.0 protocol was first released back in . This standard specified necessary signal rates of up to 1.5 megabits per second at "low speed" and 12 megabits per second at full speed. Eventually, this was replaced by USB 2.0 in . These cables had advanced to the point where their maximum (theoretical) data throughput grew to 1.2 megabytes per second.

USB 3.0 made its public debut in . This was notable due to the addition of a "Super Speed" transfer mode enabling a theoretical data transfer rate of up to 5.0 gigabytes per second.

Of course, variations of this have been made over the proceeding years. USB 3.1 was released in with increased power capabilities and data speed. USB 3.2 was released in and continued to make further improvements on the "Super Speed" mode, etc.

Advantages and Disadvantages of USB Cables

The major advantage of USB cables has to do with their versatility. As their popularity has grown, the economies of scale have helped reduce the overall cost of making USB cables and connectors. Because they are inexpensive, can be easily customized, and are able to carry high-speed data, they can be used with virtually any type of consumer electronic device as needed.

Along the same lines, USB devices are designed with the ability to carry more data faster than the other types of cables that preceded them. USB cables are typically built with one or more twisted pairs of data cables, allowing for higher data transfer speeds when compared to traditional multiconductor cables. Additionally, as the USB generations have progressed, their connectors have been downsized with more power and data being able to be transferred with decreasingly smaller connector footprints. Smaller connectors usually mean less cost and less real estate needed on your PCBA.

Perhaps the only major downside of these types of USB cables is that they don't have an unlimited lifespan, although they were never designed that way in the first place. They're inexpensive, they're effective, they're efficient. Yes, most people will replace their USB cables every few years, but that doesn't outshine the major benefits that they bring to the table.

The Most Common USB Connectors for Cables

One of the most common types of USB connectors for cables is called USB Type A. These are specifically designed to be a standard and low-cost interface. Usually, with 4 pins and a termination to “ground” or the connector “shell”, USB A connectors can transmit both power and data.

Another common interconnect type is the USB B, which is square in shape as opposed to the rectangular version that most people are familiar with.

Example of the most common USB cable connectors.

USB micro connectors are also common, especially in portable devices like smartphones, e-cigarettes, and many other types of consumer electronics. This is essentially a smaller version of the standard USB capable of transferring power and data. This interface is still very common today just as it was during the days of GPS units, MP3 players, and similar types of consumer electronics.

Common USB Cable Lengths and Wire Types

Generally speaking, the most common USB cable lengths are those manufactured at 3 feet, 6 feet, and 10 feet. This is because the types of devices that use these cables don't necessarily need to go beyond these standards. The USB charger that comes with your , for example, is very likely 3 feet in length.

Additionally, there is a maximum overall length allowed for early-generation USB protocols. The long cable has more wire and an increased electrical resistance creating a voltage drop over long distances. This can degrade signal integrity and reduce the total power transferred. Simply put, there are laws of physics that limit the maximum possible wire length that can be used for USB cables with standard copper conductor cables.

In terms of wire sizes, typically 26 AWG is used during construction, however this size can vary depending on the application. USB wire typically follows UL or another similar and readily available wire. It's important to note that some USB cables use multiconductor cables that are comprised of four discrete wires and an overall shield. Examples of this include USB Type A and USB Micro Type B. Two of those wires are used for power, while two are used to send and receive data.

Some USB cables use multi-conductor cables with up to 24 wires, with USB Type C being the prime example. This offers higher power and faster speeds when compared to previous generations as numerous differential pairs are needed.

How Overmold USB Cables are Built

Overall, USB cables are built to be inexpensive and to survive the rough handling that often comes with everyday use. Most USB cables are overmolded, so that they're as rugged and as cost-effective as possible.

Many factories maintain an array of "house tools," all of which can be used by any customer. This is particularly helpful when it comes to the connector families of USB Type A, Type B, and Type C cables. Mini and micro-USB cables can benefit from this process, too. These house tools represent cost savings and a reduction in the total amount of time it takes to make the first samples.

While saving money and scheduling on a new project is preferred, if a truly custom overmold tool is needed then this will have a small cost and timeline impact. Currently, production tooling is usually less than $2,000 per design and adds a few weeks to the total project. By considering a custom overmold tool, adding custom markings and artwork is possible. Additionally, the precise shape of the overmold can be completely customized to meet whatever design requirements exist.

Summary

Launching any new project for a custom cable assembly requires information regarding the wire specs, connector type, cut lengths, etc. Using a USB standard protocol and connector scheme helps standardize many of these variables, which can save time and money. Another benefit to using the USB standard for connectors is that this is not a single-sourced item, and there should always be stock of the raw materials. Early engagement with a full-service manufacturing partner like Epec can help review these critical cable assembly design questions before it’s too late.

Key Takeaways

Top 21 Benefits and Applications of Custom Cable Assemblies

Is standard, off-the-shelf cable not meeting your needs? When you’re dealing with a complex application and standard cable seems to be falling short, custom cable assemblies might be the way to go.

As a cable technician, you know that purchasing the right cables are essential to any application requiring cable assemblies, whether it’s for setting up a home theater system that requires a special power cable, or an industrial application that needs a custom coax.

Poor wiring, or using standard cable just to make do, can lead to improper set up and technical issues. In the case of mission-critical applications for industrial use, a glitch can result in a temporary shutdown which can spell disaster.

Sure, standard cables may work in many instances, but custom cables come with their own set of advantages that off-the-shelf cables can simply not provide.

Let’s discuss the top 21 benefits and applications of custom cable assemblies that you should know.

Benefits of custom cable assemblies

Accuracy

Custom cables are manufactured as per the specifications in the design. This makes their application extremely precise to fit into the tolerance level detailed for the assembly.

Quantity

An exact amount of cables can be ordered tailored to the needs of the application. There is no wastage, nor are any excessive cables left after the assembly is completed. The exact count for conductor, size and stranding can be optimized during the design of the assembly.

Flexibility

The length of each cable can be manufactured exactly as per the requirement of the project. This makes the set up clean without any need to hide additional cables and wires.

Accountability

The person working with the custom cable assembly will have a closer association with the cable manufacturer. The manufacturer therefore is accountable for the quality and standard of the cables that have been ordered, as well as ensures that the set up is functional as desired.

Material Requirement

Materials used for construction of the cable such as shield, insulation, jacketing material can all be specified to suit the application. Control on the material sources and manufacturing process can also be detailed in case of critical applications such as the medical industry.

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Quality Assurance

Applicable test data such as electrical parameters, tolerances, temperature performance and resistance to chemical exposure can all be supplied by the custom cable manufacturer to ensure that the cable is tested for the given parameters before assembly.

Saves Time

Custom cables save many hours which would have otherwise been spent struggling with making standard cables fit the needs of the application. Hurdles like cable length, connector ends, resistance of cables, faulty cables and mismatch of specification can all be eliminated by just ordering custom cables.

Higher Performance

Due to the fact that custom cables undergo a stringent manufacturing process and are extensively tested, they may offer higher performance as compared to their standard, bulk or store ordered counterparts. With a longer lasting life span, custom cables save money in the long run.

Multiple Functions

For specialized applications such as security and surveillance, custom cables can be manufactured to incorporate multiple functions such as power, signal, optical fiber, coax, video, cable shielding and more, all into one cable. This specialized solution takes us minimal space and is built for unmatched performance.

Additional Services

Many a times custom cable manufacturers offer additional services such as laser marking and even design support for choosing the best custom cables for your application, which could serve as a big cost saving factor.

Professional Branding

Specifications for aesthetics such as color matching, look and feel, as well as texture of the cable can be detailed to the cable manufacturer when you order your custom cable. You can even add labels for easy identification. This gives a clean, neat and tidy finish to the project making it look like the hard work of a professional.

Applications of custom cable assemblies

Medical Industries

Healthcare operations and hospitals have very detailed requirements for cables and wiring. Conditions such as high temperatures or large amount of moisture used for sterilization of medical instruments, make the cables deteriorate and disintegrate at a much faster rate. Thus, the medical industry needs custom cables that are able to sustain this repeated exposure day in and day out.

Telecommunications

Custom cables are manufactured for the digital age and broadcasting using fiber optic technology. Whether we are using our Smartphone, laptop, computer, tablet or anything that requires a network these cables help in the quick transfer of data. For cable technicians, custom fiber optic cables are excellent for meeting critical network needs when standard patch cables can’t do the job.

Military

From powering overseas military bases to securing confidential communication, to the units on the field, the military uses custom cabling and wiring for many of its branches. Also, cables used in military operations, need to endure harsh environmental conditions and perform under intense exposure, especially when on missions, so custom cables are a good choice to meet these critical requirements.

Aerospace

With the advancement of technology there is a continuous increase in the list of products needed by the aerospace industry. All digital instruments and workspaces need to have quality cables for optimum performance of any aircraft. From the hard wiring in the cockpits to the receiving units at the base, precision cables are integral to the success of the flight.

Automotive

The automotive industry is one of the largest industries that requires mass usage of cable assembly services. Proper cable assembly from the dashboard to the engine are critical for the efficient working of any vehicle.

Electronics

There’s much more that goes into electronic gadgets than just their look and style. Behind the user interface a lot of custom cables are at work to ensure that the product functions well and delivers what it’s meant to do, while at the same time being compact and user-friendly.

Utility Industry

Public utility companies serve many functions from powering homes to streetlight timings and other applications, all of which need custom cables to transmit power.

Industrial Controls

Massive machinery and hydraulics that are needed in any production line, require cables not just to transmit power but signals as well.

Sensors and Scanners

Custom cables are used widely in different devices and equipment which could be point-of-sale(POS) scanners, terminals of instruments, and automated kiosks.

Testing and Measuring Equipment

Testing and measuring devices, used in continuity testing for example, are critical in verifying whether a particular equipment, model, gadget or appliance meets required specifications. These instruments might need simple wiring all the way to complex custom assemblies for high quality and precise testing results.

Where to Buy

Since custom cable assembly specifications vary across different industries and applications, a trusted custom cable provider can offer ready stocked custom cables in popular cable types and lengths for high in-demand applications.

For detailed specifications that meet your unique needs, you can design your own custom cable by choosing your cable type, cable brand, connector types and more, that results in a cable that’s perfect for your application.

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