Customers bring their most complex challenges to DEVA, for effective solutions. When a customer needed a durable, 13 ft. low-voltage battery pack charging cable, DEVA’s was the only solution that met the challenge successfully. Where other vendor submissions failed functionality testing, our team developed a working prototype in just six weeks, and completed the first production parts in nine months. Learn more about this project and how DEVA stands out from the competition.

Project Overview

The company approached DEVA with a very specific request. They needed a UL-certified, 13 ft. charging cable for a low-voltage consumer grade Li-ion battery pack. In addition, the cable needed to wind neatly onto a 4.5 in. enclosed hub, and it would also need to withstand up to 1,000 winding and rewinding cycles.

Capabilities and Processes Applied

DEVA’s design team knew this specialized project required a multi-faceted design and a few different manufacturing techniques. The cable assembly was engineered for both charging performance and long-term durability, and incorporated copper wire and a PVC jacket.The enclosed hub and other plastic components would be made with injection molding. Finally, to make the cable retract, a watch spring mechanism was developed and integrated into the design.

Manufacturing Details

Our vetted supply chain partners were instrumental in helping us bring this project together. The project drew on several processes, including:

  • Plastic injection molding.
  • Watch spring manufacturing.
  • Cable overmolding and assembly.
  • Custom tensioning and pull testing.

Key Specifications

Our solution met the customer’s requirements and exceeded their expectations. Application details include:

  • Industry: Retractable cable assembly and winding hub for consumer Li-ion battery pack charging.
  • Overall Part Dimensions: 5 in. circumference, 1.5 in. high.
  • Materials Used: Lexan 123R, Stainless Steel, Copper wire with PVC Jacket.
  • Material Finish: Textured finish for plastic parts was built into the tooling.
  • Testing/Inspection: Pull testing, full electrical testing of cable assemblies; reliability testing of the retractable mechanism to 3,000 cycles.
  • Volume: 3,000 to 4,000 units annually.
  • Delivery/Turnaround Time: Full completed design and first production parts in 9 months; production parts run 8 to 10 weeks ARO.
  • Delivery Location: North America.
  • Standards Met: UL-certified.

Challenges and Solutions

This project required collaboration between different manufacturing disciplines to be successful. In addition to manufacturing a custom watch spring, the spring required precise tensioning for proper force during cable retraction. Unfortunately, the automatic retraction mechanism also contributes to wear and tear on the cable. A PVC jacket was determined to provide flexibility and protection for pulling the cable out and retracting it repeatedly.

Results and Customer Feedback

Our ability to deliver a functional prototype within just six weeks, while all other vendor submissions failed functionality testing, was a key factor in this customer’s decision to work with us. They were delighted with the successful completion of the project and expressed high satisfaction with every aspect of your work. The product functions exactly as intended, leading to sustained orders from the customer for over four years. They hail us as their “best supplier,” highlighting our commitment to going above and beyond expectations.

Partner with DEVA, for Your Next Innovation

This project clearly illustrates the extent of DEVA’s connections with supply chain partners, as well as our ability to coordinate efforts across vendors to create an integrated solution that works. By tapping these trusted resources, it took only six weeks to engineer and produce working prototypes.

DEVA is an ISO- and C/UL-certified manufacturer and value-added reseller of cable assemblies, wiring harnesses, and fan assemblies. We also maintain a network of vetted suppliers that provide additional materials and services to expand our capabilities and tackle simple or complex jobs that may stymie our competition.

When you have a unique application that takes a specialized solution, DEVA is up to the challenge. Contact us today to learn more about how we can help you tackle your biggest manufacturing challenges.