Injection Molding Cable Assembly

Injection Molding .Custom Molded Cable and Overmolded Cable Assemblies

Overmolding is a key process in manufacturing cable assemblies, which is both aesthetically pleasing and practical. As the name suggests, overmolding cable assebly is to seal the outside of wires or terminals, connectors, etc. with resin materials into a special shape, so that the wires, terminals, connectors, etc. are closely combined together. The advantage of this product is that it provides additional protection. Due to the use of resin materials, injection molded composite cable assemblies are usually required. When the cable is inserted into the mold, the flowing resin liquid material is formed onto the cable/wire. Cable covering molding is less costly than other methods and can also provide strain relief at the end of the cable. Improve the service life of cable assemblies.

Molding vs. Overmolding
Custom over-molding services are when we apply polymers to a connector.   The polymer provides a coating over the connector and bonds the connector to the cable jacketing.
Custom molding services are when the molded polymers provides the structure for the individual conductors.   A typical male or female connection you find at the end of an extension cord would be an example of a custom molding operation.

Any molding on cords is called “insert injection molding” because unlike a fully closed mold, the injection molds used to work on cords have to allow the cord or cable to stick out of the mold.

Injection Molding Cable Assembly(overmolding) Mainly Includes The Following Types ‌ :
1.Cable sheath ‌ 

2.Cable connector ‌

3.Cable plugs and sockets

4.Cable identification plate ‌ 

5.Cable fasteners ‌

Process of Injection Molding Cable Assembly
The process of overmolding involves two primary stages: insert molding and overmolding. Insert molding is the initial stage where the cable and connector are assembled. The assembled parts are then placed into the overmolding machine, where they are subjected to the overmolding process.
1.Insert Molding
Insert molding is the first step in the overmolding process. It involves the assembly of the cable and connector, which are then placed into the mold. The purpose of this stage is to prepare the cable assembly for the overmolding process, ensuring that it is properly positioned within the mold.
2.Overmolding Stage
The overmolding stage is where the actual overmolding process takes place. The thermoplastic material is heated until it reaches a liquid state, and then injected into the mold cavity. The molten material encases the cable assembly, forming a protective layer once it cools and solidifies.

SAISONIC's Custom Injection Molding 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 Injection Molding 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.