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USB Cable Assembly: A Manufacturer's Guide to Types, Standards, and Applications

July 24, 2023

USB cables are essential components in our interconnected digital lives, enabling data transfer, device charging, and peripheral connectivity. In this blog post, we’ll take a closer look at USB cable assembly manufacturing, the different types of USB cables and connectors available to manufacturers, how devices use each of them, and the impact these versatile connectors have on a range of applications across industries. 

What is a USB cable?

A USB cable, short for Universal Serial Bus, is a common type of cable used to connect electronic components to computers or other digital devices. It enables data transfer and power supply between devices, making it an essential tool in today's interconnected world.

Types of USB cables

USB cables are available in various types, each designed for specific purposes and device compatibility. Let's explore the most common USB cables, bearing in mind that connectors gradually get phased out as newer alternatives emerge: 

  • USB Type-A: Originally introduced in 1996, USB Type-A cables are flat, rectangular USB connections that we typically find on computers, USB hubs, and even some AC power bars. Peripheral devices like keyboards, mice, printers, and external storage devices typically use USB Type-A to connect to a computer.
  • USB Type-B: The USB Type-B, also known as a printer cable, was introduced to the market shortly after Type-A. USB Type-B cables feature square-shaped connectors with beveled corners, and provide a secure connection for printers, scanners, audio interfaces, and external hard drives. While USB Type-B cables were common in the early 2000s, they are now rarely used due to the rise of USB Type-C.
  • USB Type-C: This versatile connector is rapidly gaining popularity, with Apple now using USB Type-C for its MacBook Pro and Air, iPad Pro, and some iPhone models. USB Type-C cables boast a smaller, reversible design, making plugging in easier. They are also suitable for smartphones, tablets, laptops, and video monitors. It provides faster data transfer speeds and higher power delivery for quick file transfers and efficient charging.

We should point out that older USB cables, including USB Type-A and Type-B, operate in a master/slave connection, where one end tells the other what to do. In contrast, USB Type-C offers a two-way connection as both connectors on the cables are identical, contributing to its versatility and cost-effectiveness.

USB cable assembly manufacturing

USB cable assembly manufacturing

A USB cable assembly refers to the complete manufactured cable unit, including the USB connectors on both ends, internal wiring, shielding, and any additional components like ferrite cores or specialized overmolding.

Key components of a USB cable assembly include:

  • USB connectors (Type-A, Type-B, Type-C, Mini, or Micro)
  • Internal copper conductors for power and data transmission
  • Shielding materials to prevent electromagnetic interference
  • Strain relief and overmolding to protect cable integrity
  • Optional components like ferrite cores for noise suppression

Custom USB cable assemblies can be manufactured to specific lengths with various connector combinations, special shielding requirements, or unique overmolding designs to match product branding. This is particularly relevant for automotive, medical, and industrial applications where standard off-the-shelf cables may not meet specific requirements.

USB cable standards and certifications

USB cable assemblies must meet specific industry standards and specifications:

  • USB-IF certification requirements
  • UL certification for safety compliance
  • RoHS compliance for environmental regulations
  • Voltage and current ratings per USB specification
  • EMI/EMC compliance standards
  • IP ratings for environmental protection (when applicable)
  • Flex life and durability testing requirements

What is a Mini-USB?

Mini-USB: Mini USB-B connectors were developed as slave connectors for smaller electronic products, such as early digital cameras and MP3 players, and to connect small devices to computers. A Mini USB-B connector is roughly a quarter of the size of a USB-A connector.

Most manufacturers today have replaced Mini USB-B connectors with either micro-USBs or USB Type-C connectors.

What is a Micro USB?

Micro-USB: Micro USB-B connectors are even smaller than Mini USB-B connectors and were developed to connect to smaller camera and MP3 devices of the time. Apart from their small size, Micro-USB-B connectors also offer two small latches, which help keep the cable/connector attached to the device.

Micro-USB-B connectors are commonly found in smartphones, tablets, digital cameras, and other mobile devices for charging and data transfer.

Unlike USB Type-C, Micro-USB connectors are not reversible, meaning users must align them correctly for insertion. Micro-USBs and USB Type-Cs are not interchangeable.

What is a USB cable used for?

USB cables serve various purposes, making them essential for numerous applications. Let's explore their primary uses:

Data Transfer

USB cables enable seamless file transfers, syncing, and data backup between computers and external storage devices, smartphones, tablets, cameras, printers, and other peripherals.

Charging

USB cables are commonly used for charging mobile devices. They connect to power sources like computers, USB wall chargers, power banks, or AC power bars to recharge smartphones, tablets, and other portable devices.

Peripheral Connectivity

USB cables establish connections between computers or host devices and peripheral devices like keyboards, mice, printers, scanners, game controllers, and audio interfaces, ensuring seamless plug-and-play integration. 

Audio and Video Transmission

USB cables connect audio interfaces, MIDI controllers, mixers, headsets, microphones, and video devices, facilitating data transfer and recharging of cameras. They also support multimedia integration in digital signage, kiosks, and more.

USB cable applications

Manufacturers are leveraging USB cables for a wide range of applications in various fields. Let's explore some key areas where USB cables are commonly used:

Automotive Industry

USB connections play a significant role in vehicle infotainment systems, supporting data transfer, device charging, and multimedia integration. Users can access music, videos, and photos via smartphones, tablets, and USB storage devices in their vehicles. They also facilitate integration with features like GPS navigation, hands-free calling, and satellite radio, among others. 

Medical Devices

USB cables enable data transfer, communication, and charging between medical devices and computers, facilitating seamless integration and analysis of patient data. They are also crucial for transferring electronic medical records and medical imaging files securely, as medical devices often handle sensitive patient data that cannot be risked through wireless transmission options.

Internet of Things (IoT)

USB connections integrate smart home devices, industrial sensors, monitoring devices, and point-of-sale systems into the IoT ecosystem. They support the communication and power transmission between devices, sensors, and control modules.

Other Applications

USB cables are also widely used in industrial automation systems, point-of-sale terminals, smart agricultural implements, industrial sensors, control modules, and multimedia integration in digital signage and kiosks.

Future trends in USB cables

USB4 and Thunderbolt 4

Powered by Thunderbolt technology, USB4 offers faster data transfer, enhanced power supply, and improved connectivity. Thunderbolt 4 supports multiple 4K displays and provides more power than USB4 alone.

USB-C Adoption

USB-C connectors will continue gaining popularity due to their reversible design and compact size. They are expected to replace conventional USB connections in various devices. New legislation in the European Union has also mandated the use of USB-C connectors for all phones, tablets, digital cameras, headphones, handheld video game consoles, and e-readers by the fall of 2024. Apple has already confirmed it will comply with the new legislation, which will further accelerate the adoption of USB-C connectors across a wide range of electronic devices.

Wireless Connectivity and USB-C

Integration between USB-C connections and wireless devices is becoming more prevalent. WiFi USB hubs and USB-over-WiFi software applications enable wireless data transmission from USB devices.

Compact Bluetooth Adapters

Compact Bluetooth adapters inserted into USB-C ports allow computers to communicate with nearby Bluetooth devices.

Kingstec’s USB cable assembly manufacturing

When you work with Kingstec, you gain access to our extensive experience in engineering, logistics, and business solutions. We take pride in being a leading provider of USB cables, serving a diverse range of industries and applications.

At Kingstec, we specialize in creating custom USB cables in a range of colors, shapes, and branded logos for unique applications, including USB data loggers. Our projects have involved incorporating circuit boards into USB Type-A connectors for data logging purposes. These are then overmolded to appear as regular cables while serving specialized functions. 

Call us today to learn how your manufacturing and products can benefit from high-quality, well-designed, USB cable and connection options.

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