Custom Overmolded Cable Assemblies

Step 1: Collaborative Design & Tooling

The foundation of a successful overmolded assembly is a well-designed tool, also known as a mold. This process begins with our engineering team working closely with you to understand the specific requirements of your application. We consider factors such as the desired level of strain relief, the required IP rating, the connector type, cable diameter, and even aesthetic preferences like texture and logos. Using advanced CAD software, we design a two-part steel mold that precisely matches the geometry of your desired overmold shape. This design phase is critical, as it determines the final form, fit, and function of the assembly. Once the design is approved, the custom mold is precision-machined. While there is an initial investment in tooling (NRE), this custom approach ensures a perfect result that off-the-shelf solutions simply cannot match, and the tool can be used for thousands of production cycles, making it cost-effective for volume production.

Step 2: Cable Termination & Preparation

Before the molding process can begin, the cable assembly itself must be expertly prepared. This involves cutting the bulk cable to the precise length, stripping the outer jacket and inner conductors, and terminating the wires to the connector pins. This is typically done through high-precision crimping or soldering. This termination process is performed under strict quality control, as the integrity of these connections is fundamental to the assembly's performance. Once terminated, the connector and a portion of the cable are carefully placed and secured inside one half of the custom-designed steel mold. The mold is then closed, creating a cavity around the back of the connector that is ready to be filled.

Step 3: Injection & Curing

This is where the integration happens. We use a vertical low-pressure injection molding machine, which is ideal for the delicate nature of electronic assemblies. The chosen thermoplastic material (such as PVC, TPE, or Polyurethane), heated to its melting point, is injected under controlled pressure and temperature into the mold's cavity. The material flows around the connector and cable, filling every void and bonding chemically and mechanically to the components. The low pressure ensures that the sensitive connector pins and solder joints are not damaged during the process. After the injection is complete, the mold is cooled, allowing the thermoplastic to solidify and cure. The mold is then opened, and the newly-formed, fully integrated overmolded cable assembly is ejected, ready for final inspection and 100% electrical testing.