Custom Battery & Power Cable Assemblies
Custom battery and DC power cable assemblies with push-pull, D-Tap and other equipment connectors, engineered around your voltage, current, cable and equipment requirements.
- Push-pull & D-Tap power connections
- Custom voltage & current configurations
- Power + signal hybrid solutions
- Waterproof & overmolded options
- Custom cable, pinout & wire gauge
500+ Custom Projects
10,000+ Connector Options
Engineering Support
100% Electrical Testing
Battery & Power Cable Assembly Applications
Professional Cameras & Video Equipment
Custom D-Tap, push-pull, XLR, Hirose and DC power cable assemblies for professional cameras, monitors and related video equipment.
LED Lights & Production Equipment
Custom D-Tap and DC power cables for LED lights, production accessories and other battery-powered equipment used in professional video systems.
Battery-Powered Medical Equipment
Compact and secure push-pull power cable assemblies for portable medical equipment, battery-powered instruments and related devices.
Robotics & Mobile Equipment
Custom battery and DC power cable assemblies for robots, mobile platforms and onboard equipment requiring secure power connections.
Military & Field Equipment
Rugged, waterproof and overmolded power cable assemblies for portable military electronics, communication systems and battery-powered field equipment.
Portable Test & Measurement Equipment
Custom DC power and battery cable assemblies for portable instruments, data acquisition equipment and field test systems.
Our Battery & Power Cable Assembly Solutions
Push-Pull Battery Cable Assemblies
D-Tap Power Cable Assemblies
DC Power Cable Assemblies
Battery Pack Connection Cables
Power & Signal Hybrid Cable Assemblies
Built to Match Your Battery & Power System
- Push-pull circular power connectors
- D-Tap male and female configurations
- XLR, DC, USB and Hirose interfaces
- Battery-to-equipment connections
- Custom conductor size and wire gauge
- Custom pin assignment and polarity
- Custom cable length and branches
- Straight and right-angle connectors
- Overmolded strain relief
- Straight and right-angle connectors
Engineered for Reliable Battery & DC Power Connections
Current & Wire Gauge Matching
Connector contacts and conductor sizes are selected according to the required continuous current, peak current, cable length and operating conditions. This is particularly important for battery power assemblies, where current capacity cannot be determined from connector size alone.
Low-Resistance Power Connections
Connector contacts, conductor size, termination and cable construction are reviewed together to provide a reliable electrical path and control unnecessary voltage drop and temperature rise.
Secure Push-Pull Locking
Self-latching push-pull connectors provide quick, tool-free mating and secure locking, making them suitable for battery-powered equipment requiring frequent connection and disconnection.
Power + Signal Integration
Hybrid connector and cable configurations can combine DC power with signal, control or battery-monitoring circuits when required by the equipment design.
Waterproof Power Connections
Waterproof push-pull connector options are available for outdoor, mobile and field equipment requiring protection against water and dust.
Overmolding & Strain Relief
Custom overmolding can reinforce the connector-to-cable transition, provide strain relief and define the required cable exit for frequently handled or mobile power cables.
Materials and test requirements can be selected according to the application and customer specifications.
Power Source
Battery pack, DC power source, battery plate and power distribution equipment
Connector
Push-pull, D-Tap, XLR, DC, USB, Hirose and customer-specified connectors
Electrical Requirements
Custom voltage, continuous current and peak current
Circuit
Power, power + signal, power + control and customized hybrid configurations
Wiring
Custom pin assignment, polarity and point-to-point wiring
Harness
Point-to-point, splitter, multi-output and multi-branch
Cable Length
Customized according to equipment and voltage-drop requirements
Cable Exit
Straight, right-angle and customized configurations
Strain Relief
Bend relief, overmolding and customized cable transitions
Cable Type
Straight and coiled cable options
Identification
Labels, heat-shrink, wire numbers and customized marking
From Concept to Production
Samples or Prototype Development
Submit RFQ
The customer submits drawings, samples or technical requirements.
Technical Review
INTE-AUTO’s product manager and engineers evaluate the application and specifications.
Connector Recommendation and Confirmation
Suitable connectors are recommended according to the electrical, mechanical and environmental requirements. The customer confirms the selected connector.
Cable Recommendation and Confirmation
Cable construction, conductor size, jacket material, shielding, flexibility and other specifications are proposed for customer confirmation.
Cable Assembly Drawing and Approval
INTE-AUTO prepares the cable assembly drawing, including dimensions, wiring, connectors, cable specifications and overmolding details.
Material Availability Check
Available connectors, cables and components are checked to determine the prototype lead time.
Sample or Prototype Production
Samples are manufactured according to the approved drawing.
INTE-AUTO Testing
Electrical and applicable mechanical or functional tests are completed before shipment.
Customer Testing and Approval
- The customer evaluates the samples in the intended application and provides feedback. Once approved, the project proceeds to mass production.
Mass Production
Collect Prototype Feedback
INTE-AUTO collects the customer’s feedback on the samples or prototypes.
Engineering Review
Our engineers and product manager discuss any required improvements with the customer.
Confirm Improvements and Update Drawing
All changes are confirmed, and the cable assembly drawing is updated for final approval.
Prepare Bulk Cable and Components
Custom cables are produced, and all connectors, contacts, overmolding materials and other components are prepared.
Mass Production
Cable assemblies are manufactured according to the approved drawing and production requirements.
Final Inspection and Testing
Finished cable assemblies undergo visual inspection, electrical testing and other specified tests before shipment.
Shipment
Approved products are packed and delivered to the customer.
FAQ
Please provide the equipment application, power source, operating voltage, continuous and peak current, connector interfaces, polarity or pin assignment, cable length and operating environment.
Drawings, connector part numbers, cable specifications, photos or existing samples can also be provided for evaluation.
Connector selection should consider the required continuous and peak current, number and size of power contacts, conductor size, ambient conditions and applicable temperature-rise requirements.
For custom projects, the connector, contacts and cable should be evaluated as a complete power assembly rather than selecting a connector based only on its physical size.
Wire gauge depends on current, cable length, acceptable voltage drop, conductor material, cable construction and operating conditions.
INTE-AUTO can review these parameters together with the connector contact size before recommending a cable configuration.
Continuous current is the current expected during normal sustained operation, while peak current is a higher current that may occur for a limited period during startup or other operating conditions.
Both should be provided when selecting the connector, contacts and conductor size.
Yes. Push-pull self-latching connectors are well suited to applications requiring quick, tool-free connection and disconnection while maintaining secure mechanical locking.
The specific connector should still be selected according to current, voltage, mating-cycle, environmental and mechanical requirements.
Yes. Push-pull self-latching connectors are well suited to applications requiring quick, tool-free connection and disconnection while maintaining secure mechanical locking.
The specific connector should still be selected according to current, voltage, mating-cycle, environmental and mechanical requirements.
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