Belgium Overmolding Cable Assemblies

What are Overmolded Cable Assemblies?
Overmolded cable assemblies are cables that have been encased in molded material, such as thermoplastic or thermoset, to protect critical connection points.The material is applied directly over the junction where wires meet connectors, creating a single, sealed unit.This process strengthens the assembly, blocks out moisture and debris, and reduces the risk of mechanical failure.Overmolded designs can also be tailored in shape, color, and finish to meet specific application or branding needs.

Overmolding cable assemblies

Overmoldingcable,cable potting and cable injection molding are seemingly simple technologies that actually require extremely high levels of craftsmanship and experience.SAISONIC has been deeply engaged in the manufacturing industry of overmolding cable assemblies for many years, accumulating rich experience and forming its own unique competitive advantages.Not only do we possess rich cross-industry production experience and mature lamination process technology,but more importantly, we are committed to maximizing the advantages of overmolded cable assembly manufacturing technology through outstanding engineering capabilities,strict quality control and in-depth customer collaboration,providing customers with robust,durable,reliable and cost-effective complete solutions.

Overmolded cable assemblies offer a more robust alternative.By encapsulating cable junctions in molded material, they provide protection, improve reliability, and streamline design without compromising performance.

Application of overmolde cable assembly:

Industrial automation: Produce a large quantity of oil-resistant, chemical-resistant and tensile-resistant overmolded cables for robots, servo motors, sensors and control cabinets. 

For example, M8 and M12 molded cables

Medical : Producing components that meet medical-grade standards, with extremely high requirements for biocompatibility, non-toxicity, and resistance to repeated disinfection, such as ECG cables

Consumer electronics: Provide precise, aesthetically pleasing and high-quality injection molding cables for audio equipment,VR/AR devices, smart home devices,etc.suchas,stereo headphone cable 

Automobiles and transportation: Producing cable assemblies that are resistant to high and low temperatures, shockproof and waterproof for in-vehicle sensors, connectors,and harsh environments.

Communication and data Center: Provide strain relief and protective molded cable assemblies for high-speed data cables, such as USB cable

Advantages of SAISONIC in the production of overmolding cable assemblies
1.Multi-material injection:
Proficient in handling composite injection molding of different hardness and materials (such as TPU,TPE,PVC,Nylon,PC,ABS,silicone),solving bonding problems at material junctions.
2.Multi-color injection:
Achieve one-time molding of multiple colors for brand identification and functional differentiation, enhancing the aesthetic appeal and value of the product.

3.Precision Micro injection:
For the injection of micro connectors (such as micro-USB,Type-C),we have precise molds and strict process control to ensure no plastic overflow and no terminal damage.
4.Insert injection molding and secondary injection molding:

Skilled at perfectly encapsulating metal components,PCB boards,or other prefabricated parts into one through injection molding,forming highly integrated and reliable structures.

5.Precise mold design: 
Our mold engineers are proficient in runner design,exhaust and cooling systems, ensuring uniform material flow,no bubbles,no missing material during the injection molding process, and maintaining extremely high dimensional stability.The mold has a long service life and is well maintained.
6.Complete internal process control:
We complete the entire process from cable cutting and stripping to terminal crimping/soldering,pre-assembly,and injection molding-to final testing internally.This ensures that the quality of each link is controllable,shortens the delivery time, and enables a rapid response to engineering changes.

SAISONIC's custom overmolded cable assemblies types

1. Ferrite:Ferrite Core /Dual Ferrite 

2. Transitions:T-Mold /Y-mold

3.  Audio:Banana Plug Jacks/ DC Power Plug Jacks/3.5mm Stereo Plug

4. Strain Relief

5. Circular:M8/M12 cable
6. Right Angle Overmolded Assembly

Contact SAISONIC for turnkey custom overmolding cable assemblies solutions

If you have any questions, please contact us and we look forward to hearing from you.We have long experience in manufacturing wiring harness assemblies and cable assemblies for various industries.