Overmolding is an injection molding process where a single part is created using two or more different materials. Generally, the first material, referred to as the substrate, is covered by other materials, also known as overmold elements, during the manufacturing process.
When it comes to overmolding cables, a TPU layer is overlaid on a rigid plastic component either using the insert molding method or the multiple-shot molding technique. Overmolded cables are full assemblies that combine wires and connectors of almost any size, material, and finish into one seamless piece.
Let’s take a look at some of the advantages and applications of overmolded cables.
Advantages of Overmolded Cables
Overmolding protects internal components and ensures that cable assemblies have extended lives, even in harsh environments. Here’s how overmolded cables facilitate increased cable lifespan and reliability:
- Better flexibility at the cable exit, allowing for easier movement of the cable and connector
- Enhanced shock and impact resistance
- Creates a water-tight seal that’s in line with IP certification
- Prevents tampering as all the components are protected by a sealed resin
- Increases the overall quality and feel of cable assemblies
- Simplifies the installation process
- Provides complete strain relief and enhanced pull strength
Customizations
Apart from the advantages outlined above, overmolded cables offer complete customizability. During the overmolding process, all chosen components are placed inside a mold cavity. Molten plastic material is then injected into the cavity which conforms to the mold’s contour and solidifies around the parts.
This allows you to customize:
- The overmold color, which can be altered to meet internal color code assemblies
- A logo or company name on the mold
- The design and exit points
- The addition of LED indicator lights to reduce repair times
- The material used
Common Applications
Overmolded cables are perfect for use in rugged environments that are characterized by extreme temperatures, high-pressure wash-downs, exposure to dust and debris, and constant flex and strain. They are also more aesthetically pleasing than other wires and cables that come out of one connector.
Overmolding is used in military gear, consumer electronics, medical equipment, solar energy, and industrial/OEM applications.
Choose High-Quality Custom Cables
Contact Instruments is widely recognized as a reliable supplier of high-quality process instrumentation in Canada and the United States. Our products include electronic gauges, custom cables, pump stands, weight indicators for drilling rigs, and brass wear rings. We offer a variety of custom cables, including molded custom cables, torque turn computer cables, CCTV rugged use cables, as well as cable test boxes and junction blocks.
Call us today to find out which custom cable meets your needs.