Cable assemblies enclose vulnerable wiring in protective sheaths and incorporate a nearly unlimited variety of connectors based on the intended use. Overmolded cable assemblies go a step beyond a simple sheath by enclosing the cable or wire and connector with overmolded material.
Cable or wire assemblies are placed within a mold, which is then injected with a pressurized molten plastic. Once the material hardens, it turns into a protective layer that seals the junction between the wires/cable and connectors to reduce the risk of damage.
Customizing your overmolded cable assemblies is the best option for ensuring your electronics are protected. They are ultimately more rugged and cost-effective because the assemblies are seamless and essentially turned into just one comprehensive piece. The overmolding process allows customization of the following:
Overmold materials. Different materials imbue the assembly with different degrees of chemical or moisture resistance, heat resistance, and more. There are a variety of common plastics available for overmolding. Polyvinyl chloride (PVC) is an inexpensive general solution, but only offers minimal protection against strong acidic chemicals. Conversely, polyethylene (PE) and thermoplastic elastomer (TPE) can withstand strong acids. Polyurethane (PU) and thermoplastic polyurethane (TPU feature good resistance to weather, aging, and other harsh environmental conditions, making them ideal for outdoor applications. Material selection is based on degrees of protection desired and compatibility with wire insulation or jacket materials.
Color. During custom projects, manufacturers can add distinct colors and resins to the molten plastic. These colors can be used to match a company’s branding, color code the assembly according to instructions or regulations, or make the equipment more aesthetically pleasing. Custom colors can improve safety and organization, as well as increase the marketability of a product.
Environmental suitability. Overmolded assemblies can be built with unique features and molded layers to protect the wires against any extreme levels of wear, stress, and abrasion that may be expected in the intended operating environment.
Regulatory compliance. Some industries maintain specific regulations regarding required levels of protection for wiring and cable assemblies. Custom overmolding processes can be customized for compliance with a variety of quality standards including IPC/WHMA-A-620 and RoHS.
Customized Overmolded Cable Assembly Applications
Custom overmolded assemblies offer enhanced strain relief and suitability for a wide range of environments. They can outlast units with multiple separate parts or thin layers of protective sheathing. Custom colors also make them ideal for complex installations or environments where visibility is poor. We’re proud to serve the following industries:
Automotive.Automotive assemblies must withstand the harsh heated environments inside vehicles, exposure to dust, and contact with chemicals. Communications. Communication wiring needs to be able to withstand harsh environmental conditions to ensure stable performance.
Home electronics. Wiring for consumers needs to be able to withstand a lot of flexing and adjustment and organizational coloring strategies make DIY installations and assemblies more appealing.
Medical equipment. Wiring for medical equipment and tools need to be able to withstand constant flexing and wear. They also need to be able to withstand continuous sanitation efforts to make them compliant with hygienic standards in hospitals.
Military and defense. Custom overmolded assemblies can withstand harsh conditions and extreme weather, use in a variety of different environments, and constant flexing. They offer an ideal solution for equipment which must operate reliably in harsh and dangerous environments in a variety of situations.
Oil and gas. Oil and gas industrial facilities, both in the processing plant and on the oil field, rely on cable assemblies for machinery and equipment that operate effectively near chemicals and constant wear and tear from harsh environmental factors.
Wind and solar energy. Alternative energy systems need robust wiring systems that remain durable in interior and exterior environments.
Industrial and OEM. Overmolded wire and cable assemblies are ideal for the harsh conditions found in industrial environments.
Consolidated Electronic Wire & Cable Solutions
When you choose custom overmolded cable assemblies, you get more than custom designs and colors. This process ensures you have a cable assembly that’s the right fit for the electronics, the environment, and the relevant regulatory standards of your operation. At Consolidated Electronic Wire & Cable Solutions, our team uses high-performance materials and expertly designed systems to create assemblies that outperform and outlast other assemblies.
Consolidated Electronic Wire & Cable is a leading medical cable manufacturer that provides custom engineered and manufactured wires and cables for an extensive range of medical applications. With more than 100 years of experience, we have established a thorough understanding of the particularly rigorous standards and regulations that apply to the medical industry. Our experts can provide quality wiring solutions tailored to meet your particular needs, and our facility is designed to create cable and wiring products that meet and exceed even the most stringent industry standards.
Medical Cable & Wire Applications
At Consolidated Electronic Wire & Cable, we offer the highest quality wiring and cable on the market. Our medical cable products can be found in a variety of medical applications, from diagnostic equipment to laboratories and lighting systems.
Medical Imaging and Diagnostics
Medical diagnostic and imaging equipment requires high-performance, reliable wiring and connections to transfer information accurately and securely. Common diagnostic and imaging systems include MRIs, PET and CT scans, ultrasounds, and X-rays. This type of equipment is critical for the diagnosis and treatment of patient injuries and illness.
Medical laboratory equipment requires medical cables and wires to ensure the accurate measurement, analysis, and monitoring of patient health. It is used to help medical professionals examine bodily fluids for signs of disease or infection. Lab equipment also includes life support equipment such as dialysis machines, cardiopulmonary bypass (CPB), ventilators, and anesthetic dispensers. It can further be used to measure and track patient vitals using EEG and ECG measurements.
Treatment Units and Operation Tables
Medical cable and wire is critical for use in treatment equipment such as surgical lasers, LASIK equipment, and medical infusion pumps. Operation tables must be equipped with reliable wire and cable arrays to ensure appropriate positioning of the patient during sensitive procedures.
In addition to accurate table orientation, surgeons must have extremely bright lighting to operate safely. This requires extremely reliable and durable wire and cable assemblies that can withstand high power levels and extreme temperature fluctuations.
As automation becomes more common in medical practice, robot-assisted surgery is helping medical care practitioners provide quick, efficient, and accurate surgical procedures. Surgical robots are highly complex and require the ability to move smoothly and quickly with a high degree of precision. A surgical robotics system will require data cables to receive and transmit instructions, as well as sensor cables to transmit critical information to the operating system in real time. These cables must be highly flexible and able to withstand bending and turning motions common in surgical robotics functions.
Electronically Adjustable Hospital Beds
Adjustable hospital beds with electronic controls make it easier for patients to enter and exit the bed comfortably and safely, and provide an easy means of adjustment for comfort. Not only does this allow patients more freedom of movement, it helps healthcare practitioners move patients with a significantly lower risk of injury due to falls. Cables in electronically adjustable hospital beds must be flexible and able to operate when bent by the bed’s movement.
Hospital Lighting Units
Hospitals require highly adjustable and specialized lighting for different applications. Lights over workstations must be bright enough for healthcare professionals to read charts, while room lighting must be adjustable. Bright light is necessary for nurses and doctors to read patient charts, insert IVs and deliver injections, but the lights should be able to dim for the comfort of the patient. Medical cables are available with a broad range of designs and fixtures to ensure optimal operation for all healthcare applications.
PA and Communication Systems for Staff
Reliable communication is crucial in a healthcare environment. From requesting emergency care to communicating patient needs, healthcare professionals must be in contact almost constantly over the course of the workday. Medical cables and wiring arrays help hospitals and other medical facilities establish clear overhead PA systems for code calls, emergency requests, and paging, as well as small communication devices that can be used for direct interpersonal contact.
Contact Us for Medical Cables & Wires
For more than 100 years, Consolidated Electronic Wire & Cable has been a proud provider of quality custom solutions for wire and cable arrays for the medical industry. We offer an extensive selection of conductive wire materials of varying lengths in both shielded and unshielded designs, with coatings and color options to suit the specific requirements of your medical applications.
Contact our experts to learn more about our medical cables and discuss your customization options.
Custom-designed cable assemblies serve as critical components in many different applications, including commercial and home electronics, appliances, medical equipment, aerospace and military projects, telecommunications, automotive products, and industrial equipment.
Designing cable assemblies to ensure optimal performance is a tough enough job on its own. Having to make multiple purchase orders throughout the process only adds to the headache, wasting both time and labor. But there’s a way around this …
Beyond the Products
Consolidated Electronic Wire & Cable doesn’t just produce quality products; we also ensure that our clients’ business processes are as streamlined and efficient as possible.
One of the ways we achieve this is by processing just one invoice against multiple purchase orders (POs).
The Consolidated Advantage
Consolidated is a customer-driven, employee-owned company. All of our skilled workers are dedicated to client satisfaction and are deeply committed to constantly improving and innovating our manufacturing processes, customer support services, and product offerings. As a smaller business, we’re able to provide personalized, one-on-one service, ensuring that our customers receive ideal solutions for their exact needs.
So what does this mean for your company?
Reduced Total Cost of Procurement
Relying on Consolidated for your cable and wire needs will save you both time and money while increasing overall efficiency, as our Just-In-Time (JIT) stock program ensures fast turnarounds for every order.
Our expansive, modern distribution center is just minutes away from Chicago’s O’Hare International Airport, allowing for fast, easy deliveries to anywhere in the world.
Unrivaled Quality Assurance
Our Total Quality Management (TQM) system is utilized throughout the entire manufacturing process to ensure products meet our customers’ unique specifications and all relevant standards.
Extensive Custom Capabilities
Throughout our nearly 100 years in business, we’ve served virtually every market in the world, fulfilling unique cable requirements for companies of all kinds. Whether your order is for 5,000 feet or 1,000 pieces, we can design and manufacture a custom product to meet your exact needs.
To learn more about Consolidated’s single-invoice PO solutions for cable assemblies and discuss how we can help with your next project, reach out to the team today.