Knowledge of Cable Overmolding

Cable over-moulding is a manufacturing process that simplifies the way wires and connectors are assembled into cohesive, more durable individual units. It provides enhanced strength, protection, and versatility for a wide range of applications in various industries. Cable over-moulded assemblies can be customized in shape, size, material, and configuration, with molten PVC or other polymers encapsulating the wiring material and protecting the wires and terminals from the environment.

Cable Overmolding
Cable Overmolding

Overmolding Design Considerations

1, Material Selection: It is necessary to select overmoulding material that has the characteristics of good flow, adhesion and heat resistance appropriate for an application as well as being compatible with other materials in the cable assembly.
2, Mold Design: The moulding design has not only to ensure that the material flows evenly into the mould but also should withstand pressure and temperature at which it is injected. Mold surface should be smooth in order for cladding material not stick on the mold.
3, Molding process: The overmolding process should be optimized according to the selected material used and mold design. Moulding temperature, pressure, time need to be adjusted to adapt the properties and dimensions of molding compounds in use respectively.
4, Appearance Design: Overmolded parts should have a good appearance to meet customer requirements. The surfaces of overmolded parts should be smooth and free of burrs, and the same shade as all other parts.
5, Performance Testing: Overmolded parts need to be performance tested to ensure they meet the requirements of the assemblies they belong to. The test covers mechanical, electrical and environmental properties.

Cable assembly over-molding process steps

1, Material Selection: Selecting suitable thermoplastic or thermoset material according to application requirements.
2, Injection Molding Machine Setup: Using injection moulding machines set up storage areas (hoppers) and heating elements (barrels).
3, Material Preparation: Feed the moulding material into the heated barrel and mix this with any desired colorant.
4, Injection into Mold: The resin material is injected into the mould cavity where logos or part numbers can be added.
5, Cooling and Molding: The material is cooled and hardened in the mould to form the desired shape and features.
6, Demolding: The mould is opened, the finished product is removed, and it is ready for the next injection cycle.

These steps may vary depending on the specific cable assembly and material, but in general, this is a basic over-moulding process.

Advantages of over-molded cable assemblies

1, Tolerant of Harsh Environments: Overmolded cable assemblies are capable of working with liquids and in extreme conditions.
2, Rapid Prototyping: Using 3D printing, over-molded prototypes can be quickly and cost-effectively produced for testing before final processing.
3, Branding and Aesthetics: Overmolding allows for branding and logo design to be incorporated into the connector body, enhancing the brand image.
4, Simplified Installation: Simplify the mating process with visual indicators to minimize human error.
5, Tamper-Resistant: Adding an insulating layer to prevent tampering ensures data security.
6, Shock and Vibration Resistance: Suitable for harsh industrial environments, able to withstand shock and vibration without damaging connections.
7, Efficient Cable Management: Organize wires to reduce clutter and simplify maintenance and repair.
8, Flexible Cable Outlets: Enhanced durability and mobility where cables intersect with connectors to ensure smooth connections.
9, Regulatory Compliance: Overmolded cable assemblies can be fine-tuned and customized to meet various standards to ensure regulatory compliance.
10, Durability: Overmolding technology with strain relief improves the durability of cable assemblies.

Overmolded cable assembly applications

1, Medical Devices: Withstand constant flexing and stringent sanitation standards in healthcare environments.
2, Consumer Electronics: Reliable and adaptable solutions for electronic devices, offering customization options such as branding and custom labels.
3, Automotive: Adaptable to harsh vehicle environments, resistant to heat, dust, vibration, and chemicals.
4, Military: Ideal for demanding and hazardous military applications.
5, Communications: Achieve consistent performance in challenging environmental conditions.
6, Wind and Solar: Ensuring durability, reliable connectivity, and weather resistance.
7, Industrial and OEM: Provides reliable connections in harsh industrial environments to ensure efficient mechanical operation.

Need an over-moulded cable assembly solution?

Romtronic is China’s leading and most innovative professional cable assembly manufacturer and wire harness wiring factory. We have more than 30 over-moulding machines, if you are not sure which over-moulding is suitable for your application, please consult us.

Cable Assembly Molding Processing
Our cable over-molding processing area