Hi everyone, I’m looking for a professional "sanity check" on a custom power cable I’ve assembled for a PSU project. I’m interested in feedback as this is for a custom built PC that will use a Corsair SF1000 PSU.

Technical Specifications:
Connectors: C13 / C14 custom assembly.
Housing: 3D printed Nylon 12 FA.
Insulation: Individual terminals wrapped in Kapton tape.
Wire: 14AWG stranded copper wire, rated to 200C, silicone insulation
Measured Resistance: Constant 0.2 Ω from pin-to-pin across the assembly.

Specific Questions for the Community:

Based on the attached photo of the solder joints, does the wetting and fillet profile look acceptable for high-current AC applications?

Is Kapton tape considered a reliable primary insulator in this context, or should I transition to adhesive-lined heat shrink for better mechanical retention?

Are there specific concerns with using Nylon 12 FA for the outer housing regarding its UL flammability rating or dielectric strength in a PSU environment?

Thanks!

 

Attached picture...

 

Attached pictures...

 

It depends a lot on which country's regulations it has to pass.
You can't use black for earth in some places.
Regulations will stipulate how thick insulation has to be, not necessarily what it is made of.
Solder joints are not allowed in many places unless the cable is mechanically restrained AS WELL as soldered.
But, like that, you can't sell it in Britain.

 

It depends a lot on which country's regulations it has to pass.
You can't use black for earth in some places.
Regulations will stipulate how thick insulation has to be, not necessarily what it is made of.
Solder joints are not allowed in many places unless the cable is mechanically restrained AS WELL as soldered.
But, like that, you can't sell it in Britain.

I am in the US and this is a personal prototype that won't be sold.

 

there is one immediate flaw, at least by the standards that I had to follow: That standard was that the connection first had to be mechanically made, so that when the solder failed the connection would not part and open the circuit.
If the wires in the photos had passed thru holes in the tabs, or had been surrounded by a loop of connector material, they would pass.
The connections in the photo will fail after extended vibration and may not only open, but possibly contact the other conductors. That failure could lose a race or cause an unsafe condition.