OvermoldingSimply put, overmolding is an injection molding process in which two or more materials are used to combine the wire and connector to create a single part. To do this, the cable assembly is placed inside a mold. The first material (the substrate) is covered by the other materials in this process. The overmolding process requires a rigid plastic component to be overlaid with a TPU layer or other overmold materials using either the insert molding (a single shot) or multiple-shot molding (two-shot) technique.

Overmolding or overmolded cables are full assemblies that combine the wire and connector into one single, seamless piece. To do this, the cable assembly is placed inside a mold. Next, a molten plastic material is injected into the mold cavity. Once the plastic material cools and solidifies, it conforms to the shape of the mold and encapsulates the junction point between the connector and wire.

What are the benefits of overmolding?

Collectively, all the advantages of overmolding boil down to two things: greater lifespan and reliability. Overmolding shieldsinternal components, fortifies protective qualities and helps cable assemblies survive in even the most rugged environments. By overmolding your cable assemblies, you will:

  • Increase the flexibility at the cable exit, where most of the movement between a cable and connector takes place
  • Provide resistance to abrasion and shock or impact
  • Make cable assemblies tamper-proof by encapsulating components beneath a sealed resin
  • Provide 360-degree strain relief and increased pull strength
  • Create a water-resistant or water-tight seal that qualifies cable assemblies for IP certification
  • Improve the overall quality, appearance and feel of cable assemblies, replacing the need for expensive metal backshells
  • Simplify installation by creating a one-piece assembly with keys that act as visual indicators to assist in the mating of each pair
  • Reduce human error