Compact, durable, and fully customizable
Our overmolded Audio Plug 3.5mm Mono/Stereo Angled 90° assemblies deliver reliable connections in tight spaces. In addition, they are fully customizable: choose mono or stereo, pair with audio cable or coax, select the cable length, and finish with a free cable end or JST connector. In other words, we build according to your specs for volume production.
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Order Information
D1003215-00 – Mono, D3.5, Audio Cable, 1.5m, free ends
D1003216-00 – Stereo, D3.5, Audio Cable, 1.5m, free ends
D1003217-00 – Mono, D3.5, Coax Cable, 1.5m, free ends
D1003218-00 – Stereo, D3.5, Coax Cable, 1.5m, free
MOQ: 500 pcs (custom packaging available)
Customization: Cable type, cable length, terminals, mono-stereo
Item Description
Technical Specifications (typical)
- Plug size: 3.5 mm
- Contacts: nickel-plated brass (standard) or gold-plated (low contact resistance)
- Insulator: PBT/PA
- Strain relief: overmolded TPU
- Conductor: OFC, 26–20 AWG depending on cable
- Shielding: spiral copper or tinned braid, ≥85% coverage (audio cable); coaxial braid + foil available
- Dielectric withstand: 250 Vrms, 1 min (no breakdown)
- Insulation resistance: ≥100 MΩ @ 100 VDC
- Operating temp: −20 °C to +80 °C
- Compliance: RoHS & REACH
(Specs can be adapted to your target standard or environment.)
Key Benefits
- Space-saving 90° design – reduces strain and fits slim housings.
- Mono or stereo – wire exactly as your circuit needs.
- Built for durability – molded strain relief, nickel or gold-plated contacts.
- Noise-clean signal – shielded cable options for low crosstalk and hum.
- Production ready – 100% continuity test and visual inspection.
Typical Applications
- Headsets, intercoms, and microphones
- Audio modules, recorders, and DAC/amp boards
- Robotics and IoT devices with 3.5 mm I/O
- Test jigs and lab instruments
- Consumer electronics and educational kits
| Configuration | Options |
|---|---|
| Plug Type | 3.5 mm TS (Mono) / 3.5 mm TRS (Stereo) |
| Cable Type | Audio Cable (OFC, shielded), Coax Cable, PVC / TPE / PUR jacket |
| Cable Length | Standard: 0.3 m, 0.5 m, 1 m, 1.5 m, 2 m, 3 m Custom: Any length available |
| Cable Termination | Free Cable End (tinned/stripped) JST Plug (PH, XH, ZH series) Other connectors on request (Molex, DuPont) |
| Wiring & Pinout | Mono (TS: Tip = Signal, Sleeve = Ground) Stereo (TRS: Tip = Left, Ring = Right, Sleeve = Ground) Custom wiring available |
Production Process of Our 3.5 mm Audio Plug Assemblies
At Davantech, we ensure each 3.5 mm angled audio plug assembly meets the highest standards of reliability and durability. Therefore, our production process combines precision engineering with strict quality control at every step:
- Wire Cutting
High-precision automated machines cut cables to the exact length required. As a result, this guarantees consistency and tight tolerances, even for high-volume production. - Stripping and Preparation
The cable jacket is carefully stripped, exposing the conductor and shielding without damage. This step is crucial for stable signal transmission and low resistance. - Soldering the Contacts
Conductors are soldered to the plug terminals using controlled heat and flux. to clarify, this ensures a secure electrical connection with minimal signal loss. - Insert Moulding / Overmoulding
The soldered contacts and strain relief area are encapsulated with insert moulding or overmoulding. As a matter of fact, this process protects the solder joints, improves mechanical strength, and gives the connector a clean, professional finish. - Contact Protection and Shrink Tubing
Heat-shrink tubing or moulded insulation is applied around the contacts. This prevents oxidation, adds electrical insulation, and reinforces strain relief. - Terminal Assembly
The cable is completed with the requested termination — such as a free cable end, JST plug, Molex connector, or another interface. All crimps and insertions are checked for accuracy and strength. - Testing & Inspection
Each assembly undergoes continuity testing, polarity verification, and visual inspection. Optional pull force tests and resistance checks can be added for critical applications.
Why This Matters for Your Application
- Signal Integrity: Controlled soldering and shielding ensure low-noise performance.
- Durability: Overmoulding and shrink protection extend cable life in demanding environments.
- Customization: Every step is adjustable — from cable jacket material to connector type.
- Reliability: 100% tested before shipping, minimizing failures in the field.
