Strain Relief
Control cable bending near the connector or breakout and reduce stress at the termination point.
Custom Cable Overmolding Services
Custom Overmolded Cable Assemblies Built for Protection and Strain Relief
Cablum provides custom cable overmolding for connectors, cable exits, Y-junctions and strain-relief features. We support PVC, TPU and TPE overmolding, with tooling coordinated through qualified partners and assembly managed by our Shenzhen team.
- PVC, TPU and TPE options
- Custom shapes and strain relief
- Prototype and low-volume support
- Project-specific IP testing
Why Overmold a Cable Assembly?
Integrate mechanical protection into the cable design
An overmold can protect the termination area, improve strain relief and create a consistent interface. Final performance depends on the cable, connector, material, tooling and validation plan for the specific project.
Environmental Protection
Support sealing against dust or moisture when the complete assembly is designed and validated for the required ingress rating.
Custom Interface
Add project-specific geometry, grip features, colors or molded identification subject to material and tooling feasibility.
Material Options
PVC, TPU and TPE overmolding
Cablum can process PVC, TPU and TPE for cable overmolding. Material selection is reviewed for each application rather than assigned by a universal rule.
PVC
A practical option for many cable applications where cost, appearance and standard mechanical protection are important.
TPU
Can be considered where flexibility, abrasion resistance or demanding mechanical use is part of the project requirement.
TPE
Can support flexible strain-relief and tactile design requirements, subject to compatibility with the cable and connector materials.
Material selection: The final grade, hardness, color and compatibility should be confirmed during engineering review. Customer-specified materials can be evaluated before quotation.
Project Workflow
From design review to controlled production
Our process separates tooling, sampling and validation so that requirements can be checked before repeat production.
- 1
Requirement Review
Review the drawing, sample, cable dimensions, material, quantity and performance requirements.
- 2
Overmold Design
Define the geometry, strain-relief profile, gates, parting lines, identification and key dimensions.
- 3
Partner Tooling
Mold tooling is produced by a qualified external tooling partner and reviewed for the approved design.
- 4
Sample Build
Prepare samples and check appearance, dimensions, fit and agreed functional requirements.
- 5
Validation
Complete the project-specific inspection and test plan before production approval.
- 6
Production
Manufacture and inspect repeat orders using the approved materials, tooling and work instructions.
Lead-time note: Standard cable samples may typically be supported in 7–10 days after requirements and materials are confirmed. Projects requiring new mold tooling need a separate schedule based on tooling complexity and validation needs.
Inspection & Validation
Test the requirements that matter to the application
Inspection scope is agreed for each project. It may include dimensional, visual, electrical, mechanical or ingress-protection checks.
Visual & Dimensional
- Overmold appearance
- Critical dimensions
- Cable and connector fit
Electrical & Mechanical
- Continuity and pinout
- Pull-force checks where specified
- Bending or strain-relief evaluation
Ingress Protection
- IP67/IP68 testing for suitable designs
- Project-defined method and acceptance criteria
- Sampling according to the agreed inspection plan
Important: IP67 or IP68 is not claimed automatically for every overmolded product. Suitable assemblies can be tested and validated to the agreed requirement. Air-leak or waterproof testing is performed by sampling, not as a universal 100% inspection.
Typical Designs
Overmolding for custom cable configurations
Feasibility is evaluated from the actual interface, materials, quantities and operating environment.
Connector Backshells
Integrated protection and strain relief at cable-to-connector transitions.
Y-Junctions
Molded branch points for custom multi-leg cable and harness assemblies.
Strain-Relief Grommets
Custom profiles designed around cable diameter and bending needs.
Molded Identification
Colors, text, logos or orientation features where tooling and material allow.
Frequently Asked Questions
Planning a cable overmolding project
What overmolding materials can Cablum process?
Cablum supports PVC, TPU and TPE overmolding. The suitable material and grade depend on the cable, connector, flexibility, abrasion, environmental, appearance and regulatory requirements.
Does Cablum use low-pressure molding?
No. This service uses conventional injection overmolding. We do not present it as low-pressure molding or LPM.
Is mold tooling manufactured in-house?
No. Mold tooling is produced through qualified external tooling partners. Cablum coordinates the design requirements, reviews the tooling and manages sampling, assembly and production.
Can an overmolded assembly be tested to IP67 or IP68?
Yes, suitable designs can be tested and validated to project-specific IP67 or IP68 requirements. The test method, sample quantity and acceptance criteria must be agreed for each project.
Is every waterproof assembly air-leak tested?
No. Waterproof or air-leak testing is performed by sampling according to the agreed project inspection plan unless a different requirement is reviewed and quoted.
How long does custom overmolding take?
Timing depends on material availability, mold complexity, sample quantity and validation requirements. The typical 7–10 day cable prototype period does not automatically include the manufacture of new mold tooling.
What is needed for an overmolding quotation?
Please provide drawings or samples, connector and cable dimensions, material preferences, color or logo needs, target quantity, operating environment and required tests.
Discuss Your Application
Need a custom overmolded cable assembly?
Send your drawing, sample, quantity and performance requirements. We will review the material, tooling and validation needs before quotation.
Process Video
From Design Review to Custom Cable Overmolding
See how a custom cable assembly moves from interface review and material selection through tooling, controlled injection overmolding, inspection and project-specific validation.
- Connector and cable interface review
- PVC, TPU and TPE material selection
- Partner tooling and sample validation
- Controlled conventional injection overmolding
- Visual, dimensional and electrical checks
- Project-specific mechanical validation
AI-assisted technical visualization for educational purposes. Actual tooling, materials, process settings and validation criteria depend on the approved cable assembly and project requirements.