Electric vehicles are becoming more common, and so is the need for reliable charging cables. Learn from the experts at CDC, specialists in custom EV cables, as this guide explains what EV cables are, their history, the main types in use today, and why standards vary. Read on to learn more.
What are EV cables?
EV cables are the specialised cables used to charge electric vehicles by connecting them to a power source. But you can’t just plug an EV into any old extension lead and expect it to work: these are anything but standard cables.
EV cables are engineered to handle the high-power demands of EV charging, with robust insulation, thermal protection, and safety mechanisms built in. They also need to perform reliably in real-world environments: exposed to rain, heat, cold, dirt, and daily wear. More than just a link between car and socket, EV cables are critical infrastructure, and every detail of their design matters.
When were EV cables invented?
While electric vehicles have been around in various forms for over a century, the cables we now associate with modern EVs are a relatively recent development. In California, the J1772 connector (often called Type 1) first appeared in 2001. It was later re-engineered by Yazaki in 2008 to handle higher power, and by 2010 it had become the standard charging interface for most American EVs.
In Europe, we took a different route. The Mennekes Type 2 connector, designed in 2009 and standardised in 2011, became the official plug for AC charging across the EU by 2013. These designs laid the groundwork for EV charging as we know it and are still in use today.
Key components of an EV cable
At first glance, an EV cable might not look much different from a heavy-duty extension lead. Inside, it’s a far more sophisticated piece of engineering. At the core is the conductor, typically made of high-purity copper, chosen for its efficiency in transferring high current with minimal resistance.
Around this sits multiple layers of insulation, each serving a specific role: electrical insulation to prevent shorts, thermal barriers to manage heat, and often an outer sheath designed to resist UV, oil, and mechanical stress. Many EV cables also include shielding to suppress electromagnetic interference. Then there are the connectors, housing pins, sensors, and in many cases, data lines that allow the vehicle and charger to communicate in real time.
How long are EV charging cables?
EV charging cables come in a variety of lengths, typically ranging from about 3 meters to 10 meters. Manufacturers design cables to balance practicality with performance, making sure that longer cables still deliver power efficiently without excessive heat buildup or voltage drop.
EV charging cable types
EV cables are currently anything but standardised across the industry. Different cars, countries, and charging setups all call for different connector types, and each has its own technical requirements.
CCS (Combined Charging System)
Now the dominant standard in Europe and North America, CCS combines AC and DC charging in one plug. It’s compact, versatile, and widely supported by most new EVs.
Chademo
Developed in Japan, Chademo is an early DC fast-charging standard. It allows for bi-directional charging and is still used in some Asian and older Nissan models, but it’s being phased out in many global markets.
Type 1 (J1772)
Found mainly in North America and parts of Asia, this AC charging plug is common in older or imported models. It’s slower than DC options and typically used for home or workplace charging.
Type 2 (Mennekes)
The standard AC connector in Europe, Type 2 is also used as the base for CCS2. It’s widely supported across the EU and compatible with most public charging networks.
Tesla
Tesla uses its own proprietary connector in North America, which supports both AC and DC charging through the same port. In Europe, Tesla vehicles use the standard Type 2/CCS2 system.
GB/T
China’s national charging standard. GB/T comes in separate versions for AC and DC and is mandatory for all EVs sold in the Chinese market. It’s not compatible with non-Chinese vehicles or networks.
Why are there so many different kinds of incompatible chargers?
It comes down to a mix of regional standards, competing technologies, and how quickly the EV market has evolved. Different countries pushed their own designs early on: Japan with Chademo, Europe with Type 2, and the US with J1772 and later CCS. Each was optimised for local infrastructure, regulations, and had industry backing from car manufacturers of that region. At the same time, car manufacturers also made proprietary decisions, like Tesla in North America, to lock consumers into the brand ecosystem.
Because of this fragmented start, full compatibility across all EVs and networks is still a work in progress. It’s improving, but the legacy of competing standards is hard to shake.
Custom EV cable technology at CDC
As demand for electric vehicles accelerates, so too does the need for reliable, adaptable charging infrastructure. At CDC, our EV cable solutions are built to support the rapid expansion of the EV market across the UK and Europe, offering options that combine power and data in a single streamlined product. That means faster installation, reduced costs, and fewer complications.
Whether you need traditional power cables, SWA options for direct burial, or fully bespoke designs for specialist applications, we’ve got the expertise and flexibility to deliver. Every cable we manufacture is built to exacting standards, with a sharp focus on quality, speed, and communication throughout.
To learn how custom cables can meet your specific cabling needs, contact our expert team today, or find more resources on our blog.
