Overmolding Cable Assembly by SAISONIC

Cable overmolding manufacturer overmolded & encapsulated cable assemblies.Custom molded cable assembly manufacturer by SAISONIC

What is a overmolding cable assembly

The basic concept: Specific parts of the already manufactured cable harness or connector (usually the end, the tail of the connector, the branch point or the area that requires special protection/reinforcement) are overmolded by using the injection molding process to cover the cable assembly with one or more layers of protective or functional films or sleeves.

Manufacturing process of overmolding cable assemblies 

By using the injection molding process, the resin material heated to a molten state is forced into the mold cavity under great pressure to completely wrap the outside of the cable or connector. The commonly used mold covering materials are thermoplastic or thermosetting materials. For instance, PVC,XLPE,TPU, etc. During this processing, any preferred color can be processed by mixing colorants and resins. Molds can also be designed, including logos, product names or part numbers, which can be reflected on the cable assemblies.

Cable overmolding ( injection molding process) material
SAISONIC offers overmolded cables in a variety of plastic materials, in a variety of colors and shapes.  Usually the material of the overmolded cable include：

1.Polyvinyl Chloride (PVC)Polyvinyl Chloride (PVC)

2.Thermoplastic Rubber (TPR)

3.Thermoplastic Elastomers (TPE)

The main purpose of overmolding cable assemblies

1.Provide additional protection for cable assemblies, including insulation, waterproofing, moisture-proofing, flame retardancy, electromagnetic shielding, etc.

2.  Mechanical protection: The covering molding enables the cable assembly to withstand impact, vibration and continuous bending, be wear-resistant, fatigue-resistant, and extend its service life.

3.  Stress relief: Disperse the bending stress at the connection and branch points between the cable and the connector to prevent the conductor from breaking.

4.  Electrical insulation/isolation: Increase the insulation grade of cable assemblies or isolate parts at different potentials.

5.  Sealing: Provide sealing for the interface positions of cable assemblies.

6.  Allow the company logo and product name to be used as part of the tool to cover the mold itself, making them more aesthetically pleasing.

7.  Beautification/Arrangement: Make the appearance of cable assemblies, wire harnesses and connectors neat and beautiful.

The characteristics of overmolding cable assemblies

1.Integrated molding: Injection molding materials are directly coated on components such as cables, terminals/contacts, and metal parts of connectors, forming a seamless and integral assembly

2.High precision and complexity: Molds can produce components with very complex shapes, precise dimensions, and fine structures (such as clips, sealing grooves, guide keys, cable clamps, and chambers).

3.Outstanding sealing performance: Molten plastic can fully fill all gaps under high pressure, achieving extremely high environmental sealing grades (IP67, IP68, IP69K are common).

4.Outstanding mechanical strength and protection: The formed plastic shell itself has a very high strength and can provide excellent impact resistance, pressure resistance, torsional resistance and vibration resistance.

5.Large-scale and efficient production: Once the mold is completed, the production cycle of a single component is short, making it suitable for large-scale standardized production. After cost allocation, the unit cost is low.

6.High consistency: The automated injection molding process ensures extremely high dimensional and performance consistency of the products.

7.High initial investment: The cost of mold design and manufacturing is expensive, and the development cycle is relatively long.

Process of overmolding 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 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.