It starts with a faint whiff—barely noticeable at first. Something warm, maybe even electrical. But within minutes, your high-end PC setup, anchored by the monstrous RTX 5090, begins to smell like burning plastic. For a few unfortunate users, this isn’t just paranoia. It’s real. And it’s happening more than it should.
The graphics card power cable melting issue is not new to the scene. RTX 4090 users had already raised red flags about the 12VHPWR connector’s instability. Despite Nvidia’s shift to the updated 12V-2×6 standard for the RTX 5090, the early weeks of 2025 have brought fresh reports: power cables melting at both ends, with visible bulging on the PSU side. This isn’t isolated to one brand or one build—gamers and content creators across platforms are sounding the alarm.
One user, running an RTX 5090 Founders Edition with a third-party MODDIY adapter, reported a complete meltdown while gaming. The GPU connector showed extensive scorching, but it was the PSU-side bulge that raised eyebrows. This wasn’t the result of improper installation or loose cabling. It was a secure fit, stress-tested, and previously flawless on an RTX 4090. So what changed?
The RTX 5090’s increased power demands—hovering around 575W under load—are pushing connectors closer to their design limits. Even with the 12V-2×6 update claiming better safety tolerances, the reality appears more complicated. Industry insiders now point to uneven current distribution across the cable’s 12V pins. Internal resistance varies per wire, which means some pins carry more load than others. In controlled tests, this imbalance led to cable temperatures soaring above 150°C.
That’s not a small oversight. When power isn’t evenly spread, heat builds up fast—especially near the PSU end where airflow tends to be limited. The result? Melted plastic, damaged connectors, and in some cases, unusable GPUs. While no widespread recall has occurred yet, Nvidia remains tight-lipped. Silence only fuels speculation. Is this a manufacturing defect? A design flaw? Or a problem with third-party cable makers cutting corners?
In fairness, not every user is experiencing these issues. But the pattern is enough to make cautious builders rethink their power strategy. Forums are now filled with debates about safe wattage margins, the trustworthiness of non-OEM cables, and whether ATX 3.0 PSUs actually meet the thermal demands of these next-gen cards.
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What complicates things further is how subtle the symptoms can be before failure. A faint smell. A flicker on the screen. Maybe a stutter mid-game. Nothing definitive—until the cable’s fried and your PSU has a blackened scar to prove it. That’s the risk with silent hardware failures: they don’t announce themselves until it’s too late.
Those who’ve avoided damage so far are doubling down on prevention. Many are ditching extensions and adapters altogether, opting instead for direct-connect ATX 3.0 power supplies that offer native 12V-2×6 support. Others are investing in temperature monitoring tools and external sensors, hoping to catch abnormalities before something melts. Meanwhile, modders are even 3D-printing clips and shrouds to minimize cable movement and tension—just to give their builds an extra layer of security.
But this raises a bigger question: should a premium GPU require this much DIY safeguarding? At this price point, buyers expect reliability out of the box. The 5090 isn’t a fringe product—it’s Nvidia’s flagship, aimed at professionals and hardcore gamers who rely on their machines not just for fun, but for work.
Unfortunately, until a clear technical bulletin or formal recall appears, the burden rests on users. Nvidia’s silence might stem from internal reviews or hesitation to fan the flames (literally), but it’s clear something is off. Whether it’s the connector design, cable quality, or PSU compatibility, the combination is volatile enough to deserve immediate attention.
So is your GPU at risk? If you’re running the RTX 5090 with a third-party or extension cable—especially from brands without rigorous testing protocols—it might be. If your PSU isn’t ATX 3.0 certified with native 12V-2×6 support, the chances go up. And if you’ve noticed even the slightest electrical smell near your rig, shut it down and inspect every connection. The damage may already be underway.
GPU power delivery isn’t a glamorous topic, but in 2025, it’s becoming one of the most critical. As performance thresholds climb, engineering tolerances shrink. And while raw power might win benchmarks, long-term stability wins trust.