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Why is Customized Computer Connectors and Cables Better?

May. 26, 2025

Why do modular PSUs use proprietary connectors and cables?

Pardon my potential noobee question, but...

I did search online, but the discussion seems to end with "I don't know, but here are 20 posts that talk about how much trouble you can get into by using the wrong cables from the wrong manufacturer". It doesn't seem to be as pressing for tower builds since there is so much room to hide excess cable length that you rarely need to deal with custom cables (lots of money to be made in cable "extensions", though). This question seems more pressing for SFF builds where standard cables are just atrociously too long. The question when asked in a generic context also seems to revolve around "I would like this so I can easily swap PSUs in my tower case" which isn't very pressing because it is just a convenience, but the issue of "my SFF case is so full of proprietary cables that my fans can't spin" is a bit harder to ignore.

I ran into this with my recent Ghost S1 build, and while luckily there is a supplier who makes bespoke cables for the case, ordering the cables has an unnecessary extra complication of having to specify the exact model of PSU being used. (It would likely need to be specified anyway because the cable lengths are tuned to match the positions of the connectors, but the wiring shouldn't need to be customized on top of that.)

And, here's the thing. The other end of the cables are standardized, and you can buy generic cable extensions as a result. That is OK for tower builds that can easily hide the bulky supplied cable and use an attractively sleeved extender that peeks out through a wiring port, but it isn't the best solution for that use case. And widely available generic extenders don't help at all for SFF builders that need shorter cables. So, if the manufacturers can meet a standard at the far end of the cables, why not meet it at the socket on the side of the PSU case?

I can think of a number of issues that come up with trying to define a standard, such as:
  • Not all MB use a 24-pin, but you typically get a 24-pin cable anyway so with most PSUs you already need to deal with "what if I don't have a 24-pin ATX socket?"
  • Many PSUs share connectors for the 4+4 CPU connector and the 6+2 PCIe connectors which have different wiring. This could be dealt with either by just having a dedicated CPU output and separate PCIe outputs, or as my PSU did - just have the outputs set up for the CPU needs and have the 6+2 rewire the connections in the cable bundle.
  • Not all builds use the molex or the SATA cables any more and it isn't clear how many of which a given build would need. On the flip side of that coin, though, most PSUs have a single set of accessory outputs that you either plug a cable with 3-5 molex connectors or a cable with 3-5 SATA power connectors on. The conversion seems to be achievable just by cabling, but what doesn't exist is a standard for what the PSU will output so that such cables could be easily supplied by third parties.
And, to repeat myself, they do provide a standardized connector in any case. They just put a lot of unnecessary wire ahead of that standard.

I don't see any monetary reason to be proprietary with these connections, at least not from the PSU manufacturer's perspective. They already have to supply a set of cables in the box because of their proprietary choices anyway and they have to oversupply because not all cables get used in any build. While it may be less convenient to have to buy cables separately, I for one would be quite happy to buy a modular PSU with no cables (hopefully a few bucks cheaper) and then find the specific cables I need at reasonable lengths for my build. That search is difficult, if not fruitless, due to the lack of any standard on the PSU side of those cables. Even if they continued to supply a bunch of cables in the PSU product boxes, it would make it much easier to fully customize a build if you didn't have to deal with the many PSU output standards.

One could argue that some custom cable builders might lose business, but they typically offer much more value than just knowing how to wire for your PSU, and I'm sure the reduced complexity in ordering and making the cables would simplify their business anyway.

What am I missing?

Actually, here is a related question/partial solution. If you can convert from a proprietary connector to a standard connector along a cable, how about just doing it with connector inserts instead? Provide extremely short plugs that convert the "output port type A" to a PCIe connector and then use a PCIe extender. I've seen vendors sell 2-inch long "shorty 24-pin cables" for Corsair PSUs for instance and those could be coupled with an extender if you need something a little longer, but that could easily be done at the PSU case level. You get a PSU, a bunch of plastic adapter plugs (kind of like the Apple power bricks that have a chunk that you replace for international plugs) and possibly some standardized extender cables...?

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.

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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.

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