Knowledge of Cable Overmolding

Cable over-molding is a manufacturing process that simplifies how wires and connectors are assembled into cohesive, more durable individual units. It provides enhanced strength, protection, and versatility for various industry applications. Cable over-molded 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.

Overmolding Design Considerations

1. Material Selection: An overmolding material must be selected with good flow, adhesion, and heat resistance, appropriate for the application, and compatible with other materials in the cable assembly.
2. Mold Design: The molding design must ensure that the material flows evenly into the mold and withstand the pressure and temperature at which it is injected. The mold surface should be smooth so the cladding material does not stick.
3. Molding process: The over-molding process should be optimized according to the selected material and mold design. Molding temperature, pressure, and time must be adjusted to the properties and dimensions of molding compounds.
4. Appearance Design: Overmolded parts should look good to meet customer requirements. The surfaces of over-molded 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 to which they belong. 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: Injection molding machines are used to set up storage areas (hoppers) and heating elements (barrels).
3. Material Preparation: Feed the molding material into the heated barrel and mix it with any desired colorant.
4. Injection into Mold: The resin material is injected into the mold cavity, where logos or part numbers can be added.
5. Cooling and Molding: The material is cooled and hardened in the mold to form the desired shape and features.
6. Demolding: The mold is opened, the finished product is removed, and it is ready for the next injection cycle.

These steps may vary depending on the cable assembly and material, but generally, this is a basic over-molding process.

Advantages of over-molded cable assemblies

1. Tolerant of Harsh Environments: Overmolded cable assemblies can work with liquids 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 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: We offer reliable and adaptable solutions for electronic devices, with 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.

Do you need an over-molded cable assembly solution?

Romtronic is China’s leading and most innovative professional cable assembly manufacturer and wire harness wiring factory. We have over 30 over-moulding machines, so if you are unsure which over-moulding machine suits your application, please consult us.

Sam Wu

Sam Wu is the Marketing Manager at Romtronic, holding a degree in Mechatronics. With 12 years of experience in sales within the electronic wiring harness industry, he manages marketing efforts across Europe. An expert in cable assembly, wiring harnesses, and advanced connectivity solutions, Sam simplifies complex technologies, offering clear, actionable advice to help you confidently navigate your electrical projects.