An overmolded cable assembly is a type of cable assembly, which is seamlessly constructed to combine the cable and the connector into a single cable assembly. The process of overmolding a cable involves injecting molding. It utilizes a molten material that is injected into a mold cavity. This molten material conforms to the contour of the mold cavity, and solidifies into a desired shape when cooled.
Custom Solutions for Overmolded Cable Assemblies
The mold cavity can be designed with markings to produce custom molded cables. Custom cable molding options can include a company name, logo, extended area for strain relief, and flanges to be used as attachment points.
Custom cable molding also allows to encapsulate cable connectors in almost any shape. Also, the cable assembly can be produced in various materials, colors, and finishes. Primarily thermoplastic materials are utilized to produce custom cable assembly solutions. These include:
- Polyvinyl chloride (PVC)
Rubber or ABS (Acrylonitrile-Butadiene-Styrene) material is also used for certain unique applications.
How are Overmolded Cable Assemblies Produced?
The production process involves premolding, potting, and overmolding. This is followed by a careful review in order to determine the perfect combination of characteristics and performance to meet the customer’s expectations.
Generally, a two-cavity system is used to produce overmolded cable assemblies. In most cases, each cavity is identical that creates the same shape. Instead, unique forms of cavity can also be used to create different aspects of the assembly during a single cycle. A particular application of this includes an initial pre-shot of non-colored natural materials, which is followed by a colored, finishing material for the outer mold. Moreover, overmolded cables can be designed with straight, right-angle, or any type of connectors for custom applications.
Overmolded Cable Assemblies offer Enhanced Features
Overmolded cable assemblies can enhance your application by offering the following features:
- Flexible support
- Abrasion resistance
- Increased pull strength
- 360 degree strain relief
- Water, moisture, and heat resistance
- Increased EMI (Electro Magnetic Interference)
Speak to a manufacturer to understand how custom overmolded cables can improve your applications.