Latest / Hardware Startups with Fexingo: Devices, Robotics, and Manufacturing Tech Companies / How Hardware Startups Use USB-C to Simplify Devices
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- Lucas: If you've bought a new laptop or phone in the last couple of years, you've probably noticed the charger cable looks the same. It's that rounded, reversible usb c plug. But for hardware startups, moving to usb c isn't just a convenience—it's a design decision that ripples through the entire product. Luna: Right, and it's not just about the connector shape. There's power delivery, data protocols, and the fact that one cable now needs to work across devices with completely different power requirements. Lucas: Exactly. And if today's episode helps you think through that decision for your own product, we want to keep these conversations ad-free and accessible. If you find value in what we do here, you can support the show at buy me a coffee dot com slash fexingo. That link helps us keep digging into the specifics that matter for builders and operators. Luna: Yeah, it honestly makes a difference. Okay, back to usb c—Lucas, where should a hardware startup even start when deciding whether to use usb c? Lucas: Start with power. usb c Power Delivery, or PD, can deliver up to 240 watts now. But your device might only need 15 watts. The problem is, negotiating that power requires a dedicated PD controller chip, which adds cost and complexity. Luna: So you're basically paying for overhead you might not use. I've seen some IoT sensor startups stick with micro usb just to avoid that chip. Lucas: Exactly. But there's a trade-off. The European Union's mandate for usb c on portable electronics, effective this year, means that if you want to sell in Europe—and most hardware startups do eventually—you'll have to adopt it anyway. So you might as well design it in from the start. Luna: But isn't there a middle ground? Some chips are simpler, like ones that just handle 5 volts at 3 amps. Lucas: There is, and that's what many early-stage products use. They implement what's called usb c without PD—just basic 5 volt power. That's fine for small sensors or wearables. But if your device needs fast charging, you need the full PD negotiation. Luna: Then there's the data side. usb c can carry USB 2.0, 3.0, Thunderbolt, DisplayPort—all over the same connector. How do startups decide which protocols to support? Lucas: It comes down to what data your device needs to move. A smart thermostat probably only needs USB 2.0 speeds to talk to a computer for configuration. But a camera doing high-speed video capture might need USB 3.2 or Thunderbolt. The controller chip cost scales with the speed. Luna: And the certification process is another layer. If you claim USB 3.2 compliance, you have to pass usb if testing, which costs thousands of dollars. Lucas: Right. Many startups skip certification initially and just advertise 'usb c compatible' without promising speeds. It's risky but practical when you're shipping low volumes. Luna: Let's talk about the physical design. The usb c receptacle is deeper than micro usb, which can affect how thin your device can be. Lucas: That's a real constraint. The connector body is about 3.2 millimeters deep, and that's before you add the PCB footprint. Some ultra-thin products have to use a 'mid-mount' connector that sits partially inside the board stack-up. Luna: Or they go with a 'reversible' but proprietary connector—like what some smartwatch makers do. But that defeats the whole purpose of usb c. Lucas: Exactly. And one more thing: the cable itself. Not all usb c cables are equal. A cable rated for 60 watts might not handle 100 watts. Startups should include a quality cable in the box, or at least specify what's needed. Luna: There's also the issue of e-markers. Those are chips inside the cable that tell the device its capabilities. For high-power cables, they're required. Luna: Have you seen any startups do something clever with usb c to differentiate? Lucas: Yeah, Framework Computer is a great example. They make a modular laptop where the usb c ports are on interchangeable modules. You can swap them for different port configurations, but the core is always usb c. That gives users flexibility while standardizing on one connector type. Luna: That's clever. Another one I like is Fybr, which makes smart lighting controls. They use usb c for both power and data, but they also let you daisy-chain devices over a single cable. It simplifies installation in commercial buildings. Lucas: Right, and that brings up a key point: usb c's alternate modes. DisplayPort Alt Mode lets you output video over the same cable. So a startup building a portable monitor can use usb c for both power and video, eliminating the need for separate HDMI and power jacks. Luna: But implementing DisplayPort Alt Mode requires a multiplexer chip. That's another line item on the BOM. Lucas: It is. But it can also reduce the number of overall connectors, which saves on assembly and enclosure costs. So there's a trade-off. Luna: Let's talk about the EU mandate for a second. It requires usb c for a wide range of devices—phones, tablets, cameras, headphones. That's a big shift for startups that used to ship with micro usb. Lucas: It's actually a tailwind for startups, in my opinion. It standardizes the ecosystem, so you don't have to guess which connector will be dominant in two years. And it forces you to design for a single port, which can simplify your SKU management. Luna: But it also means you're competing on a level playing field. You can't differentiate by having a 'better' connector anymore. Lucas: True. But your differentiation should come from the product, not the port. And honestly, having a universal port is a selling point for consumers who are tired of carrying multiple cables. Luna: What about reliability? usb c connectors have a rated life of 10,000 insertions, same as micro usb. But the smaller pins inside are more prone to damage if someone yanks the cable sideways. Lucas: That's a real concern for rugged devices. Some startups use reinforced connectors or add strain relief features. But ultimately, usb c is a consumer-grade connector. If you're building something for industrial use, you might need a different approach. Luna: So what's the final advice for a hardware startup listening today? Lucas: Start early. Decide on your power and data needs first. Pick a usb c controller chip that matches those needs without over-engineering. And consider certification—even if you don't get certified initially, design your PCB so you can certify later without a redesign. Luna: And don't forget the cable. Include one that's properly rated for your device's power draw. It's a small cost that prevents a lot of support headaches. Lucas: One last thing: usb c is still evolving. The new USB4 standard pushes speeds up to 40 gigabits per second, and it's fully backward compatible. So if you design with a good controller today, you're setting yourself up for future-proofing. Luna: That's a solid takeaway. Thanks, Lucas. And thanks to everyone listening. If you're building hardware, we'd love to hear how you're handling the usb c transition. Lucas: Yeah, drop us a line. And if today was useful, consider supporting the show at buy me a coffee dot com slash fexingo. It really helps us keep these conversations going.