Volume ODM · Built to drawing
Low-Cost Cable Assemblies
An economy line for high-volume connection leads: USB charging cables, DC power leads and magnetic watch charger cables built to your drawing at a unit cost driven by volume, tooling reuse and design for manufacture — not by thinning the specification.
- Program type
- Volume ODM · contract builds
- Typical volume
- 10,000 pcs and up (confirm per RFQ)
- Connectors
- USB-A · USB-C · DC barrel · magnetic pogo pin
- Build basis
- Customer drawing or approved sample
- Length
- Set per order
- Jacket
- PVC · TPE · braided (per drawing)
- Compliance
- Per destination market (confirm per build)
- Packaging
- Bulk · retail, per order
Specification table
This category groups our volume-priced builds. Listings are added here as each program is released, so the table below describes how a low cost cable assembly is quoted and built rather than claiming a catalogue that is not in place yet. Engineering-led, build-to-print harnesses stay in DC Plug Power Cables and Custom Wire Harnesses; this line is for programs where volume is the main cost driver. Every value here is confirm per RFQ.
| Parameter | Standard build | Available on request |
|---|---|---|
| Connector | USB-A, USB-C, DC barrel, 2-pin and 4-pin magnetic pogo heads | Any connector to a sample or customer drawing |
| Magnetic pitch | Per drawing; 7.62 mm is a common watch-charger interface | Custom pitch and keyed housings |
| Conductor | Stranded copper, gauge set from current and run length | Tinned copper for humid environments, quoted separately |
| Length | Cut to order; 1 m is a common charging-lead length | 0.2 m to 5 m, coiled or cut lengths |
| Jacket | PVC or TPE, color matched to order | Braided, halogen-free, low-smoke compounds |
| Overmold | Existing tooling reused where the geometry fits | New tooling quoted separately; 3,000+ tooling sets built since 2012 |
| Strain relief | Molded boot at both ends | Custom boot geometry, pull test recorded per drawing |
| Electrical test | Continuity and short-circuit check on every build | Hi-pot and insulation resistance reports |
| Compliance | Per destination market, confirm per build | CA Prop 65, RoHS and REACH documentation on request |
| Packaging | Bulk PE bag and carton | Retail box, barcode labels, custom print |
Typical applications
Kids smart watch charging leads — magnetic pogo-pin cables supplied alongside the watch, where the unit cost is multiplied across a large production run.
Consumer USB charging cables — USB-A to USB-C and USB-C to USB-C leads bundled with consumer electronics or sold as accessories.
DC power leads — barrel-plug cords for routers, set-top boxes, LED strips and small appliances, built to the plug dimension on the drawing.
Promotional and bundled accessories — high-count orders where packaging, color and printing matter as much as the electrical build.
Service and replacement parts — repeat runs of an existing lead, where reusing the tooling and the drawing keeps the unit price stable over time.
Related reading
- How to prepare a custom cable assembly RFQ — the details that let us quote a volume build without a second round of questions.
- USB-C cable versions and Power Delivery — what changes between a charge-only lead and a PD-rated assembly.
- How to select a DC barrel plug — plug dimensions, polarity and conductor sizing for DC leads.
Questions buyers ask
Does low cost mean lower specifications?
No. Unit cost comes from volume purchasing, tooling reuse, design for manufacture and automated cut, strip and crimp steps. Conductor, plating, jacket and testing stay as written on your drawing. Where a cost-down option exists, we quote it as a separate line item rather than substituting it silently.
What quantity qualifies for volume pricing?
Typically 10,000 pieces and above, but the threshold moves with the connector, length and tooling involved. Prototype runs of 1 to 50 pieces can be built before a volume order so the sample is approved first. All quantities and prices are confirm per RFQ.
Can you support compliance for children's products?
Documentation is assembled per destination market and per build, for example CA Prop 65, RoHS or REACH when requested. We do not claim certifications that have not been issued or verified for the specific assembly, so the requirement is confirmed in writing before production.
Do you publish list prices?
No. This is a quote-based site. Pricing is tiered by quantity, tooling and specification; send the drawing, target quantity and destination market through the RFQ form and we reply with a written quote.
Have one built to your drawing
Send the connector part numbers, length, target quantity and destination market. We review manufacturability and the cost drivers in writing before any tooling spend, and we tell you up front what we cannot do.