Recently, we finished turnkey OEM (original equipment manufacturing) for our client, providing AI server contract manufacturing from prototypes to bulk production, from PCB fabrication, component sourcing, PCB assembly, custom accessories including high-power cables and prong connectors, box-build assembly, and testing until the delivery of finished AI servers ready to use. The AI server is at a high power of 24KW, so our custom power and cable solutions also support this power.
Ready to view our power and cable solutions for AI servers? Let's start!
Power and Cable Solutions
The computing demand decides the power demand, and the power demand decides the cable specifications.
The higher the electrical power, the stronger the computing power, the higher the cable specifications. This is not a guideline but a hard constraint.
A single CPU today can draw 350 to 500 watts, and each DDR5 memory stick adds another 10 to 15 watts. When you multiply that across 6 CPUs and 96 memory sticks, the power easily exceeds 20KW, and the cable becomes a critical part of the system, not just an accessory.
In an AI server, the mainboard connects to an external power supply unit called the AST. The AST then powers the CPUs and memory sticks for all computing tasks. Based on your actual computing requirements, meaning how many CPUs your AI server runs and how many memory sticks it supports, the OEM turnkey electronics contract manufacturer PCBONLINE provides matching power and cable solutions.
The most basic power solution for AI servers, which we successfully implemented several years ago, runs at 32A and 380V, delivering 12KW. This configuration supports 2 CPUs and 32 memory sticks.
The required cable specification for this 12KW AI server is 5 × 6 AWG, meaning five conductors of six American wire gauge, which is about 13mm2.
The five conductors support a three-phase five-wire system, which reduces neutral current and improves overall efficiency.
Six AWG copper cable carries about 35 to 40A safely in a 40 to 50℃ server cabinet environment, leaving a comfortable margin over the 32A draw.
Currently, we have managed a significantly higher power and cable solution at 63A and 380V, delivering 24KW. This powers an AI server running 6 CPUs and 96 memory sticks.
The cable specification for this 24KW server moves up to 5 by 4 AWG or even 5 × 2 AWG, depending on the cable length inside the rack. Four AWG carries roughly 65 to 75A at the same elevated temperature, while two AWG is reserved for longer runs exceeding five meters or for higher thermal margins.
Moving from 12KW to 24KW introduces real engineering challenges beyond simply picking thicker wire.
At 63A, ordinary screw terminals create unacceptable contact resistance, so we require ultrasonic welding or hydraulic crimping for every connection. The insulation must be upgraded from standard PVC to cross-linked polyethylene or silicone rubber rated for 125℃ because continuous 24KW loads push cable surface temperatures to 60 or 70℃ inside the rack.
Voltage drop also becomes a serious calculation. For a 2m cable run using 4 AWG at 63A and 380V alternating current, the drop per conductor is roughly 0.4V, which is acceptable. But at 5 meters, the same configuration forces an upgrade to 2 AWG or a complete rearrangement of the power distribution path.
Every 24KW cable assembly also requires either a 63A slow blow fuse or a type C miniature circuit breaker, and we strongly recommend integrating current transformers for real-time monitoring. Loose connections or aging terminals create an imbalance between phases before they cause outright failure, and monitoring catches that early.
If you are customizing cables for a 24KW AI server, you should specify tinned copper for oxidation resistance, ultrafine stranding for flexibility, an outer diameter under 18 millimeters to fit standard PG36 cable glands, and a shield combining twisted pairs, aluminum foil, and tinned copper braid to suppress inverter noise. Every finished assembly must pass a dielectric test at twice the rated voltage plus 1000V, which comes to 2000V alternating current for one minute.
Looking ahead, the next step for AI server power is not just higher current but higher voltage. The next generation designs are moving to 105A × 380V = 48KW. But new problems appear in DC arc suppression and creepage distances. Even copper cables with proper sizing generate too much heat, and liquid-cooled cables with internal coolant channels are already in development to carry 100A or more without cooking the surrounding components.
You can check the custom cables we tailored for the 24KW AI server. Unlike standard power cords from a catalog, every solution we build at PCBONLINE is derived directly from your processor count, memory count, and physical cable length inside the rack. That is how we turn power demand into something you can plug in and trust.
AI server Accessory: Custom High-Power Prong Connector
Besides the custom cable, the accessory connector for the 24KW AI server is also custom, which is a prong connector. The above picture is the custom high-power connector PCBONLINE provided for the AI server we made. The connector isn't a standard data center plug but a heavy-duty industrial-grade power connector, matching the IEC 60309 standard for three-phase power, heavily utilized for high-density environments like AI servers.
Looking closely at the red plug face, we can see a 5-pin layout: 4 standard pins and 1 larger, elongated pin. The prong connector for the 24 kW AI server is a Three-Phase plus Neutral and Earth (3P+N+E) configuration.
- 3-phase pins (L1, L2, L3): Distributes the massive power load across three distinct alternating currents, which drastically reduces the current (amperage) required per wire compared to single-phase.
- 1 neutral pin: Handles any unbalanced loads between the phases.
- 1 ground pin: This is the longest prong. It is designed to make contact first when plugged in and break contact last when unplugged, ensuring the system is always grounded for human and hardware safety.
In the international standard for industrial plugs (IEC 60309), the red color is specific. It designates a voltage rating between 380V and 480V AC. In our case, the connector is designed for 380V.
Besides, there is a thick rubberized locking ring on the collar in the custom connector. It means a high IP rating - IP67 watertight. It prevents accidental disconnects and protects against dust or liquid cooling spills.
The grey segmented boot where the thick black cable enters the plug body ensures that pulling, bending, or the sheer weight of the heavy-gauge copper wires won't compromise the internal terminations.
One-Stop AI Server OEM Manufacturer PCBONLINE
PCBONLINE provides one-stop AI server manufacturing, including HDI PCB fabrication and assembly, box-build assembly, custom connectors, and custom cables.
Founded in 2005, PBONLINE has two large advanced PCB manufacturing bases and one PCB assembly factory.
AI server PCB fabrication with HDI via-in-pad copper filling for GPU designs with 24+ layers.
We provide one-stop AI server PCB manufacturing, including component sourcing, PCB fabrication, assembly, testing, and system integration.
SMT assembly with fine-pitch BGA placement accuracy and custom reflow profiles for warpage-free soldering.
100% X-Ray inspection, functional testing, and burn-in testing for guaranteed reliability.
We have rich experience in impedance control, oven temperature control, and assembly fixture designs.
Supporting IC programming in the Cloud way, manipulated by you, and protecting your intellectual property.
High-quality PCBA manufacturing certified with ISO 9001:2015, ISO 14001:2015, IATF 16949:2016, RoHS, REACH, UL, and IPC-A-610 Class 2/3.
At PCBONLINE, we can help our clients reduce costs while achieving the highest levels of performance and reliability. If you feel interested in AI server PCBs from PCBONLINE, send your inquiry by email to info@pcbonline.com.
Conclusion
AI servers are high-power and require custom connectors and cables. PCBONLINE provides power cable and connector solutions besides AI server OEM manufacturing. If you are looking for a trusted partner for AI servers, power connector/cable solutions, contact PCBONLINE for turnkey OEM manufacturing.
PCB assembly at PCBONLINE.pdf
