An overmolded cable assembly combines the connector and cable in a single design. A molten material is introduced into a mold cavity, which assumes its form on cooling. The color of the molten material can be matched to the color of equipment or cable jack being used. The types of material used for overmolding are rubber, ABS plastic, PVC, PP, PE and macro melt.
4 Important Features of an Overmolded Cable Assembly
Below are four key attributes of an overmolded cable assembly.
- Improved Protection from Abrasion and Weather Elements: During overmolding, all sensitive electrical components are encapsulated, which makes them resistant to abrasion and harsh weather elements. Thus, overmolded cables are considered cost-effective alternatives to conventional cables with black shell and EMI foil. In various industrial verticals, overmolded cables are often subjected to rough use. So a basic idea of the application environment and appropriate material to be used will help an overmolding assembly manufacturer to manufacture the right product. For example, Polyurethane is used for overmolding cable assemblies used in the military and healthcare sector. Polyurethane is abrasion resistant, has a high load capacity, and can withstand high temperature.
- Customization: An overmolded cable assembly is customizable. There permutations and combinations for materials, colors, wire types, and style options are endless. Custom colors, configurations, shapes, and imprints allow OEMs to achieve the highest aesthetic standards. A customized overmolded cable may feature a company name or logo.
- Improved Shelf Life: Overmolded cable assemblies have an improved shelf life than traditional cables because the overmolding offers complete strain relief, high pull strength, and flexible support at the cable exit.
- Compact Integration and Lighter Equipment: When compared to traditional cable assemblies, over molded electronic assemblies are smaller and allow OEM to reduce cost and the size of their equipment. Additionally, overmolding allows inclusion of circuit analysis resistors or reverse polarity protection diodes, PC board assembles, and more.
Most cable assembly manufacturers delivering custom overmolded cable assemblies follow production steps such as potting, premolding, and overmolding to determine the abrasion resistance, waterproofing, and electrical performance of the final product. Customized overmolded cables can reduce the total cost of production and improve performance. No doubt, Overmolded cable assemblies will add value to any electrical application with the above-mentioned attributes.
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