DC to DC Cable
- CCTV, Routers, and LED Strip Fit a precision 5.5mm barrel
- Using pure copper conductors: the on-voltage stably loss and high durability of the connection
- Multiple AWG Options (18-24AWG): Any current level from solar to a handful of milliwatts.
- Designs with Right-Angle & Coiled | To save space, minimize stress, and enable installation.
- Hi-Pot & Pull Testing: Thorough testing of every batch for safety and mechanical reliability
- Customization for OEM/ODM Projects — working with your specs on length, gauge, and connectors
- Factory Direct Pricing: Super low wholesale prices with flexible minimum order quantities.
- ISO 9001:2015 Certified– Consistent, High Quality Manufacturing Process
- Quick Sample & Bulk Supply: Dependable supply chain for both prototyping and high volume fases of production.
- Multifunctional Everywhere: Best for CCTV, solar, LED, routers, automotive, and industrial.
DC to DC Cable | DC 5.5×2. 1mm & 5.5×2. 5mm Male To Male Power Cables | Custom & Factory
In the world of electronic devices and systems, a solid, accurate power connection is not only an afterthought but an obligation. B2B clients, from OEMs paneling together parts to distributors, the essential pieces, the quality of a DC to DC Cable can mean life and death for product performance. Bespokecable is a manufacturer of standby, standardized high-performance DC power cables providing consistent power to where it is needed most. By honing in on the most common and versatile connector types, such as DC 5.5 x 2.1mm and DC 5.5 x 2.5mm cables, make sure you’re equipped to cover all applications, from security cameras to routers to networking equipment to point-of-sale systems.
We know that one size does not fit all. That is why we offer the traditional male-to-male format in standard straight and right-angle for added space-saving or long–reach flexibility, and in our coiled configuration. As a factory and manufacturer directly in China, we deliver high-quality, reliable products at competitive wholesale/bulk rates through stringent quality controls and can customize. From a basic DC plug cable to a more specialized solution, Bespokecable is the go-to provider of robust power connectivity throughout your application.
Technical Specifications Table
| Feature | Specification |
| Product Type | DC to DC Cable, DC Power Cable, DC Barrel Connector Cable |
| Connector Type | DC Plug (Male) |
| Connector Sizes | 5.5mm x 2.1mm, 5.5mm x 2.5mm |
| Connector Style | Straight Plug, Right-Angle (90-degree) Plug |
| Cable Type | Straight Cable, Coiled (Retractable) Cable |
| Standard Length | 1 meter, 1.8 meters (Custom lengths available) |
| Conductor Gauge (AWG) | 24AWG, 22AWG, 20AWG, 18AWG (2-core) |
| Conductor Material | Bare Copper/Stranded Copper |
| Insulation | PVC (Standard) |
| Jacket Material | PVC or Rubber (Customizable) |
| Rated Voltage | Usually 12V/24V, up to 30V DC |
| Current Rating | Varies by AWG (e.g., 18AWG supports higher current than 24AWG) |
| Polarity | Center Positive (+), Center Negative (-) available on request |
Products Show & Comparison of DC to DC Cable
- Six items for your reference.
Uncompromising Quality in Standardized Connectivity
The DC barrel connector is a worldwide low-voltage DC power standard; for example, 5.5mm outer diameter with inner pin sizes of 2.1mm or 2.5mm (or at times larger). We manufacture high-quality DC-to-DC cable male-to-male products that deliver superior performance and reliability in the electrical industry. The first cable uses high-purity copper conductors to reduce voltage drop, while the oxygen-free copper (OFC) strands provide greater conductivity. Two precision-machined brass contacts, plated with gold or nickel to resist corrosion and form a repeatable low-resistance connection each time you plug it in. The PVC or rubber jacket offers flexibility, abrasion resistance, and protection against normal wear & tear, allowing our cables to be used for both fixed installations and applications with frequent handling.
A Cable for Every Setup and Use Case
To help out with typical connectivity scenarios, we propose five key models to best suit your requirements — meaning that you’re sure to locate the correct DC power cord for your needs:
- DC 5.5 x 2.1mm Cable (Male to Male): The industry workhorse. Best suited for making a wall adapter connection to devices like routers, monitors, or external hard drives, when an in-line connection works best.
- DC Coiled Cable (Straight to Straight): Easy cable management without compromising on reach length. The roll-up coil design prevents tangles and is the best solution for test benches, service carts, or any other applications where cable length varies.
- Fixed to Right Angle DC 5.5 x 2.1mm Cable: Solves clearance issues. The 90-degree plug keeps the cable under the device, saving space and reducing stress on your DC Jack over time—ideal for confined spaces or mounted equipment, since everything else should be elevated!
- DC 5.5 x 2.5mm Cable (Straight to Straight): for devices with the larger 2.5mm center pin, usually with higher current devices, some brands of laptops, and larger audio/video equipment.
- Right Angle to Right Angle Coiled Cable | DC 5.5 x 2.1mm: The ultimate solution for tight spaces on both ends! This setup is ideal for equipment that will be rack-mounted or devices whose power port is recessed or shrouded by other connectors.
Customization and Scalable B2B Solutions
Of course, we provide all of our usual lines, but the strength of a manufacturer is found in customization. Disclaimer: We understand that your project may have specific needs. Our DC barrel connector cables are highly customizable. Here you have a few options:
- Cable Length: Standard 1m and 1.8m lengths available, any custom length possible in bulk quantities
- Wire Gauge (AWG): Select 2*24AWG, 2*22AWG, 2*20AWG, or 2*18AWG for your current requirements, based on safe operating limits and minimal power dissipation.
- Connector Polarity: Center-positive (standard), center-negative optional
- Cable Jacket: Standard PVC, ruggedized PVC, or flexible rubber can be selected depending on environmental requirements.
- Packaging: All quantities available with polybags or custom retail packaging.
So, why source your DC cables from Bespokecable?
Bespokecable is a reliable source of supply & more than this, it is a partner you need. Our in-house manufacturing, in parallel with our ISO 9001:2015 certification and stringent QC process, ensures that all DC power extension cables meet quality standards. B2B solution and support to our clients in:
- Direct Factory Pricing: Bid farewell to middlemen and buy at wholesale rates.
- Quality Assurance: Designed and tested for continuity, insulation resistance, and pull strength.
- Flexible MOQs: From small prototyping runs to bulk production.
- Expert Support: Help is at hand, allowing you to verify specifications and answer technical questions.
Call Bespokecable when you need reliable DC power supply cables or custom low-voltage power cables photos for your next order of DC connector cables. Depend on us to fuel your innovation
The most essential difference between the DC 5.5×2.1mm and DC 5.5×2.5mm plugs lies in the diameter (inner diameter) of the center pin: the former is 2.1mm, while the latter is 2.5mm. Although the external metal cylinder diameters of both are 5.5mm, and they look almost identical, the 0.4mm difference directly affects the stability and safety of the electrical connection.
AWG (American Wire Gauge) refers to the wire’s thickness. A lower number indicates a thicker wire (i.e., lower AWG). Thicker wires (18AWG) have lower resistance, thus can carry more current over a longer distance with less voltage drop. For longer runs or high-current devices, select a lower AWG (e.g., 18 AWG or 20 AWG). 22 AWG or 24 AWG is sufficient for short runs and low-power designs.
A right-angle (90-degree) DC plug is aimed at saving space and mechanical stress. This type lets the cable run flush alongside or mounted to the back of a device, which makes it great for tight installs, wall-mount racks, and situations where a straight plug may become bent or broken.
Coiled DC cables (or retractable cables) are ideal for setups needing a clean cable management solution where the length needed may differ. They stretch when pulled and retract neatly, so there are no tangles. Typical uses are test equipment, service/repair kits, portable with docking stations, and anywhere a professional appearance is important.
Our standard DC power cords are center (+). This is the uppermost polarity. NOTE: If you do need center-negative polarity, we can create cables as Custom orders.
Yes, we recommend a sample test. For your testing purposes, we can offer samples of our standard DC-to-DC cable male-to-male models. Ship samples, please contact our sales team
We have a flexible MOQ that allows us to support small B2B clients with their small orders and scale up to large businesses. Strictly speaking, that can be low for normal products. For fully custom cables, the MOQ will vary depending on those details. To learn more, talk with the sales team about your needs.
You need 3 things:
- Plug Size (ex. 5.5×2 1mm).
- Polarity (normally center-positive).
- Voltage/Current specs (to determine the proper wire gauge).
The label on the DC input jack or in the user manual generally contains these details. We are there for you to help verify based on your device model as well!
More About DC to DC Cable of Bespokecable
Products Testing
Each DC-to-DC cable from Bespokecable is subject to a stringent multi-stage testing protocol to guarantee utmost reliability & safety. A sample is taken from the production batch and tested in the same way as all shipments before any order leaves the factory. Initially, electrical integrity is checked with a continuity and polarity test to confirm that everything’s hooked up correctly and wired to an industry-standard center-positive voltage. Next is the hi-pot (dielectric withstand) test, which applies high voltage across the cable insulation to verify that it can endure surges and avoid shorts. This leads to physical robustness, as tested by a pull test on the DC barrel jack, which can be easily cabled under normal stress. With coiled cables, the cycle of retraction and extension is repeated to help withstand wear and tear. Last but not least, by testing the voltage drop and ensuring it is stable under working conditions with a 12V load on the cable assembly. Thus, providing a tested, robust DC-to-DC cable solution. This extensive testing procedure ensures that each cable complies with our stringent requirements for electrical safety, mechanical strength, and reliable power transfer.
Installation Guide
Fitting your Bespokecable DC-to-DC cable is as easy as this. For a safe and trustworthy connection, please just remember these steps:
- Confirm Compatibility: Always validate that the plug size (5.5×2. 1mm or 5.5×2. Ensure that both the size (5.5mm x 2. This text is generally found printed next to the port on your device.
- Power Off: Both the power (adapter, PS) and the device that will receive it (router, monitor) must be powered off or unplugged. This protects from interference or damage from a live connection.
- Connect the DC barrel jack cable’s cable plug into the corresponding input port on the device. The plug will fit right in with a little push. Do not force it. With right-angle connectors, you will want to orient the cable correctly so that it fits well and doesn’t put any strain on the connector.
- Connect Power Supply . Insert the female-to-male DC-to-DC cable into your compatible power adapter or power supply unit through its DC output port.
- Power On. The first step is to insert the power adapter into a wall outlet. Then, turn on your device. The device must boot normally.
- Safety Important: Always use a power adapter whose voltage matches and provides at least as much current (Amps) as the microphone current (Amps) specified for your device. A good, high-quality 12V DC-DC cable has already been moved to an under-rated adapter, causing device slip or overheating of the adapter.
User Experience (Customer Feedback)
Bespokecable DC-to-DC Cables: As a small office network system integrator, I standardized on the Bespokecable brand for all my deployments, and every experience has been pleasant. The DC barrel jack cable connectors snap securely in place and feel solid and tight-fitting — the opposite of what people usually identify as a failure point when soldering on cheap cables from earlier versions. That reliability is an absolute must for equipment operating around the clock.
For the wall-mounted networking gear that accommodates a DC connection, we utilize two varieties of the 5.5 x. 2.1mm cable with one in a straight-to-right angle configuration and some others as needed, depending on mounting requirements. The 90-degree plug really is a game-changer; it means the DC-to-DC cable can run straight up the wall, removing the awkward bend and strain that can lead to the port and/or the cable breaking over time. The cabling was much more secure and looked a lot more professional.
We can order in bulk as needed (20AWG spec is required for longer runs), which gives us a consistent approach to ensuring stable voltage delivery. For procurement, the quality level is consistent, Esterline’s specs are straightforward, and the cables perform as expected, so many fewer support calls related to power. If there is any project that requires a well-made, dependable DC power cable, we always look to Bespokecable.
Learn more our AC Power Cords, please click here!
In B2B procurement, the smallest part is usually the one that determines whether the format stops working. A DC-to-DC cable is not merely a wire; it is the means of delivering power to your devices. The fact is that whenever you are powering a fleet of security cameras, designing a custom LED installation, or integrating power for industrial machinery, choosing the wrong cable can cause recurring problems like voltage drops and overheated wiring, or even full system failures.
At Bespokecable, we believe you deserve more than just a cable. As a manufacturer and supplier, we know this equation is crucial to your work. The following guide outlines all mandatory specifications—from connector sizes to wire gauges and application specifics—so you can make the right decision for your business.
1. Decode the Connector: Size and Type
The primary cause of DC disconnection failures is physical incompatibility. The outer and inner diameters (OD x ID) of DC barrel connectors are denoted by the OD x ID sizes used in the industry.
Standard: 5.5 x 2.1mm vs. 5.5 x 2.5mm
The 5.5 x 2.1mm connector is the common standard on most consumer electronics. It is the preferred DC power solution for everyday devices like standard Router DC power cables, CCTV cameras, and LED strips. Although the 5.5 x 2.1mm connector is common, some devices that need a higher stable output current, for example, certain laptops or specialized industrial equipment, use the 5.5 x 2.5mm connector instead.”
- Compatibility Warning: a 2.5mm plug may physically fit a 2.1mm socket (usually quite loosely), but is NOT appropriate for high-current applications because of increased resistance and heat generation if used this way [making it less than ideal for high-power use]. The plug size must always match the item’s DC jack.
Straight vs. Right Angle (90 Degrees)
This is the resulting calculation space, a huge limiting factor in B2B installations.
- Straight plugs: The best option for open spaces where the cable is traveling straight out from the device.
- Right–Angle Plugs: Ideal for tight spaces, wall-mounted equipment, or rack installations. This takes pressure off the port and keeps the cable from sticking out awkwardly.
Coiled vs. Straight Cables
Coiled cables that give a “retro” look, and spring-like flexibility are also available for applications requiring flexibility, such as a Guitar pedal DC cable board for musicians who must move equipment. Straight cables are also recommended for permanent installations, like a CCTV power cable installation, as they are cheaper and simpler
2. The first thing we need to take a look at is the Saddle Wire Gauge (AWG) and how much current it can handle
American Wire Gauge (AWG) is a number that indicates wire thickness; the higher the number, the thinner the wire. A lower AWG number means a thicker wire.
- 24AWG/22AWG: Best for low current devices such as sensors, small LED strips, and Router DC power cable connections in short distances.
- 20AWG/18AWG: Definitely, you will need it for the big power applications. For long cable runs, a heavy-gauge Solar cable is required to reduce voltage drop. These losses are especially pronounced when running DC solar from a panel to a charge controller or to an RV appliance.
The Voltage Drop Factor
Voltage drop is the loss of electrical pressure as electricity moves along a wire. A larger drop the longer the cable and the thinner the wire. A critical reduction, as seen here for sensitive electronics, could lead to a malfunction. If you know your cable run is longer than 3 meters, you should always choose a thicker-gauge (lower AWG) cable.
3. Cabling for Your Industry Application
There are different needs across industries. These are the steps to follow when choosing the correct cable for certain situations:
CCTV power cable: Security & Surveillance
- Requirement: Stability and weather resistance.
- Standard:5.5 x 2.1mm (Recommendation) For Cable Run Less Than 10 meters Use 24AWG For Cable Run Greater Than 10 meters Use 20AWG or Use 18AWG to Make Sure Enough Power is Fed into the Camera(At Nights when IR Lights are Operating)
Renewable Energy (Solar DC cable):
- You need: Resistance to UV and high current
- Tip: In large-scale solar, specialized PV cables run to connect solar generators to appliances (such as a Starlink DC power cable setup) — use 18 AWG or thicker for variable loads.
Lighting (LED strip power cable):
- Requirement: Aesthetics and flexibility.
- We recommend thinner cables, such as 22AWG or 24AWG, which are generally sufficient for very low-voltage LED strips; however, they should have a connector strong enough to handle the total strip amperage.
Networking (Router DC power cable):
- Requirement: Zero downtime.
- Comments: High-quality pure copper conductors are a must, as power fluctuations may cause interference and data transmission issues.
Mobile & Marine (Car power cable/ RV DC cable/ Starlink DC power cable)
- Requirement: Vibration resistance and durability.
- Focus: Right-angle connectors can help maximize space inside vehicles. Overvoltage from an attached high-power antenna can run through 18 AWG Starlink DC power cables in RV setups, and even when the engine is running, we want to ensure a reliable amount of current still flows.
Music & Audio (Guitar pedal DC cable)
Requirement: Daisy-chaining capability and isolation.
Suggested: Standard 5.5 x 2.1mm with center-negative cables. The coiled versions are popular here for stage portability.
Battery Systems (Battery DC cable):
- Requirement: High current burst handling.
- Guidance: When installing a device directly to a Battery DC cable terminal, always use thick 18AWG or better, 16AWG cables; otherwise, the wire will act as a fuse in the event of a direct short.
4. Quality Matters: Why Choose Bespokecable?
And, when sourcing in bulk, the quality of DC-to-DC cable directly impacts your brand. Lower-priced cables may be made with Copper-Clad Aluminum (CCA) — this means greater resistance and higher operating temperature than pure copper.
We use high-purity copper to improve conductivity in our devices during cable manufacturing at Bespokecable. We test our cables for continuity, insulation resistance, and pull strength. Our customization options are vast, including custom lengths, wire gauges (18 AWG to 24 AWG), and connector configurations ( straight, right-angle, coiled).
- Introduction: Internal Resources to Meet Needs of Higher Capacities.
- Selecting the right DC cable is only one aspect of your power solution. For complete compatibility and safety, we recommend you check our wider selection of power products:
- See our full offering: Go to our Power cords section for all types of power solutions offered by your business.
- More Power Cords Options: If your project also requires standard mains connections, you can browse our wide selection of international plug types in our AC Power Cords category.
- Regional Information: If your customer requires UK-specific connections, such as BS1363-compliant cables, visit our UK Power Cords product page for all relevant specifications and details.
Conclusion
Choosing the right DC to DC cable means balancing connector style, wire gauge/ampacity, and application-based requirements. Knowing the subtleties of AWG ratings and connector sizes, you can ensure your devices are in prime condition without anything being lost again or the hardware being burned!
Custom power solutions — whether you require a rugged Solar DC cable for use in an off-grid project, or a reliable Guitar pedal DC cable for your latest audio application, Bespokecable is your partner of choice when it comes to high-quality, ultra-reliable custom power cables. Get in touch with our team today for your bulk needs or to procure a sample for testing.
