Shenzhen Vistar Electronics is a professional DC power jack manufacturer, supplying a comprehensive range of 5.5mm, 3.5mm, and 2.5mm barrel connectors. Our DC power jacks are available in various mounting styles including PCB mount, panel mount, and right-angle, with options for IP67 waterproofing, current ratings from 2A to 10A, and full RoHS compliance.
| Connector Type | Pin Count | Mounting Style | Current Rating | Voltage Rating | Mating Cycles | Waterproof Rating |
|---|---|---|---|---|---|---|
| Standard SMT | 6/9/16/24 Pin | Surface Mount | 3A-5A | 30V DC | 10,000 | No |
| Standard DIP | 6/9/16/24 Pin | Through-Hole | 3A-5A | 30V DC | 10,000 | No |
| Right Angle | 6/9/16/24 Pin | SMT/DIP | 3A-5A | 30V DC | 10,000 | Optional |
| Vertical | 16/24 Pin | SMT/DIP | 5A | 30V DC | 10,000 | No |
| Waterproof | 6/16 Pin | SMT/DIP | 5A | 30V DC | 10,000 | IP67 |
| High Current | 6/16 Pin | SMT/DIP | 5A-10A | 30V DC | 10,000 | Optional |
2A to 10A current ratings for low-power to high-power applications
5.5×2.1mm, 5.5×2.5mm, 3.5×1.3mm barrel sizes available
Waterproof options for outdoor and harsh environment use
SMT, DIP through-hole, right angle, panel mount options
Gold-plated contacts, 5,000‑10,000 mating cycles lifespan
RoHS 3, REACH compliant, suitable for worldwide export
With over a decade and a half of experience, Vistar has perfected the design and manufacturing of tactile switches, serving thousands of OEMs across consumer, medical, automotive, and industrial sectors.
All our tactile switches are produced under ISO 9001 certified quality management systems and fully comply with RoHS 3 and REACH SVHC regulations — ensuring safety and environmental responsibility.
From actuator height and operating force to waterproof sealing and LED illumination, we tailor every tactile switch to your exact specifications — with in‑house tooling and engineering support.
Accelerate your product development with quick‑turn samples and direct engineering feedback. We ensure your momentary tactile switch design is validated before moving to mass production.
With robust inventory management and logistics, we guarantee on‑time delivery for projects of any scale — from prototype quantities to high‑volume production of SMD / DIP tactile switches.
Every tact switch undergoes rigorous testing to guarantee consistent operating force, contact resistance, and mechanical life — rated up to 100,000 cycles.
A DC power jack — also known as a DC barrel connector, DC power connector, or DC socket — is a cylindrical electrical connector used to deliver external direct‑current (DC) power to a wide range of electronic devices. It is one of the most common power interfaces in consumer, industrial, and medical electronics. The connector typically consists of a hollow cylindrical outer sleeve (negative) and a centre pin (positive), with standard sizes like 5.5×2.1mm and 5.5×2.5mm.
DC power jacks are available in multiple mounting styles, including PCB mount, panel mount, SMT, and through‑hole (DIP) versions. They come in right‑angle, vertical, and straight orientations to accommodate different PCB layouts and mechanical designs. At Vistar Electronics, we manufacture and supply a comprehensive range of DC barrel connectors that meet ISO 9001, RoHS, and REACH standards.
A DC barrel connector works by establishing a conductive path between the power supply’s plug and the device’s internal power circuitry. The plug is inserted into the jack, creating two independent electrical contacts: the outer sleeve (usually ground) and the centre pin (positive voltage). Inside the jack, a spring‑loaded centre contact and a resilient outer contact ensure reliable electrical connection even with repeated mating cycles.
Many PCB mount DC jacks also include a third pin — a switch contact that detects plug insertion. This allows the device to automatically disconnect an internal battery when an external power supply is connected, or to enable/disable internal circuits. This feature is widely used in battery‑powered consumer electronics, routers, and portable instruments.
The most common DC barrel jack sizes are 5.5×2.1mm and 5.5×2.5mm. The first number (5.5mm) is the outer diameter of the barrel, and the second (2.1mm or 2.5mm) is the centre pin diameter. Other sizes include 3.5×1.35mm (used in portable devices like handheld radios), 4.0×1.7mm (common in older laptops and power adapters), and 6.3×3.0mm (used in medical and industrial power supplies).
Choosing the correct size is critical: a 2.1mm plug will fit loosely in a 2.5mm jack, causing intermittent connection and potential arcing, while a 2.5mm plug cannot be inserted into a 2.1mm jack. Always match the plug and jack diameters precisely to ensure safe and reliable power delivery.
When designing a product, one of the first decisions is whether to use an SMT DC power jack or a DIP (through‑hole) DC jack. SMT (Surface Mount Technology) jacks are designed for automated reflow‑soldering processes. They are smaller, allow for higher‑density PCB layouts, and significantly reduce assembly costs in high‑volume production. However, they offer slightly lower mechanical pull‑strength compared to through‑hole versions.
DIP (through‑hole) DC jacks have pins that pass through the PCB and are soldered on the opposite side. They provide superior mechanical anchoring, making them ideal for products that experience frequent plugging/unplugging, heavy cables, or vibration. They are also easier to hand‑solder for prototyping and low‑volume production. Both styles are available in right‑angle and vertical orientations to suit your specific board layout.
Panel mount DC power jacks are designed to be mounted through a chassis or enclosure wall using a threaded bushing and hex nut. They are commonly used in power supplies, industrial equipment, medical devices, and audio gear where the connector needs to be accessible from the outside. They typically feature a durable metal or plastic housing with a threaded collar for secure fastening.
PCB mount DC power jacks, on the other hand, are soldered directly onto the circuit board. They are the preferred choice for compact consumer electronics like routers, set‑top boxes, CCTV cameras, and LED drivers. Both panel‑mount and PCB‑mount versions are available with waterproof (IP67/IP68) and locking options for demanding environments.
For applications exposed to moisture, dust, or outdoor conditions, waterproof DC connectors with IP67 or IP68 ratings are essential. These DC power jacks incorporate silicone gaskets, sealed internal contacts, and corrosion‑resistant materials to prevent water ingress and ensure long‑term reliability.
Typical applications include marine electronics, outdoor CCTV cameras, LED street lighting, medical infusion pumps, and industrial sensors. Vistar Electronics offers a range of waterproof DC barrel connectors with custom thread lengths and seal materials to meet your specific IP requirements.
DC power jacks are found in virtually every electronic device that requires external DC power. Common applications include:
The performance and longevity of a DC power jack depend heavily on the materials used. Contact materials are typically phosphor bronze or brass, plated with gold, tin, or silver to reduce contact resistance and prevent oxidation. Gold plating is preferred for high‑reliability and low‑voltage applications, while tin plating is cost‑effective for general consumer use.
The housing material is usually a high‑temperature thermoplastic such as PBT (polybutylene terephthalate) or Nylon (PA), with UL94 V‑0 flame retardancy. These materials offer excellent electrical insulation, mechanical strength, and resistance to soldering heat. For panel mount jacks, metal housings with nickel‑ or zinc‑plated finishes provide additional durability and EMI shielding.
At Vistar Electronics, our DC power jack manufacturing process begins with precision stamping of contact terminals from phosphor bronze strips, followed by selective gold or tin plating. The contact terminals are then assembled into the injection‑moulded thermoplastic housing. For SMT versions, the jacks are packed in tape‑and‑reel carriers for automated placement.
Every batch undergoes rigorous testing: contact resistance (≤30 mΩ), insulation resistance (≥100 MΩ), dielectric withstanding voltage (1000V AC for 1 minute), and mechanical endurance (5,000–10,000 mating cycles). Our ISO 9001‑certified quality system ensures consistent traceability and defect‑free delivery.
Vistar Electronics provides comprehensive OEM and ODM services for DC power jacks. We can customize:
Our engineering team works closely with you from concept to production, providing 3D models, technical drawings, and pre‑production samples. We support low‑volume prototyping as well as high‑volume mass production with competitive lead times.
Vistar Electronics has been a trusted DC power jack manufacturer for over a decade, serving customers across consumer electronics, industrial automation, medical devices, and telecommunications. Here’s why leading brands choose us:
Whether you need a standard 5.5×2.1mm DC jack for a consumer product or a custom panel mount waterproof DC connector for an industrial system, we have the expertise and capacity to deliver. Contact us today to discuss your requirements.
Outbound dofollow reference: For industry standards and detailed specifications, refer to the Switchcraft DC Power Jacks & Plugs guide and the Wikipedia DC connector article for additional technical background.
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