Category Archive: Molded Cable Assemblies

How Are Cable Assemblies Overmolded?

Overmolding adds strength and resilience to a cable assembly so that it can withstand more extreme environments than it otherwise could. The cable overmolding process combines and seals a cable with a connector, resulting in a unified part that adds protection to its internal components.

Learn more about how cables are overmolded, the materials used during the manufacturing process, and the benefits of overmolded cable assemblies.

Cable Overmolding Materials

Common overmolding materials used in cable overmolding include:

  • PVC: Polyvinyl chloride or PVC is one of the most widely used thermoplastics for cable overmolding. PVC has a soft, rubber-like texture and high flexibility.
  • TPU: Thermoplastic polyurethane or TPU has a softer texture than PVC and comes in a wider array of colors. TPU is also more pliable and has a greater low-temperature flexibility, making it more stable amidst temperature changes.

Cable Overmolding Process

Overmolded assemblies are manufactured through injection molding, a manufacturing process that forces material into a mold cavity under pressure. The process starts when a storage area or hopper is filled with plastic resin, and an injection ram delivers the material into a barrel, where the plastic is heated to a liquid state.

Through a variety of methods, such as color compounding or master-batching, color is added to the resin. Inside the cavity, the material will cool and conform to the shape and design features of the mold, that may include logos, part numbers, and trade names.

Benefits of Overmolded Cable Assemblies

An overmolded cable assembly provides a host of benefits, including:

  • Tamper-Proof Construction: Overmolding makes cable assemblies tamper-proof by encapsulating components. Unlike standard cables, overmolded cables have an extra layer of insulation that makes it harder for unauthorized personnel to interfere with or cut the cables.
  • Long Service Life: Overmolded cable assemblies are highly durable and long-lasting. They are protected from outside elements like extreme temperatures, abrasion, dust, water, dirt, debris, chemicals, and moisture, improving performance and enhancing cable assembly life.
  • Enhanced Cable Assembly Processes: Overmolding makes the assembly process more efficient and secure. This efficiency allows production costs to be reduced.
  • Shock and Vibration Resistance: With a robust housing and stable connections, overmolded cables can withstand shock and vibration without damage.
  • Flex and Strain Relief: By overmolding your cable assemblies, you can improve resistance to strain at the cable exit, where most of the stress between a cable and connector occurs. Cable overmolding also provides 360° strain relief and increased pull strength. The outer casing acts as a buffer between the inner wires of the cable and the external elements, protecting connector terminations and wires from damage over time.
  • Cable Management: Overmolded cable assemblies can have a soft, tactile feel when handled manually and make it possible for the cables to be easily managed.

Contact Consolidated Electronic Wire & Cable for Custom Overmolded Cable Assemblies

Overmolded cable assemblies are no longer the rigid plastic they were decades ago. Overmolding materials are soft, tactile surfaces that are easy to handle and organize. They provide flexibility, strain resistance, durability, customizability, and strength to meet the most demanding cable applications. Overmolded cable assemblies are ideal for your custom design projects to enhance the protection of the assembly.

At Consolidated Electronic Wire & Cable, we provide custom overmolded cable assemblies for nearly any application. As an ISO 9001:2015 certified company, we are industry leaders in Total Quality Management (TQM) and are RoHS compliant. This ensures that our production process and customer service meet the highest quality standards. Contact us online or call us at 1-800-621-4278 for more information about our overmolding capabilities. To start your project, request a quote.

Overmolded Cable Assemblies & Customization

Overmolded Cable Assemblies - Consolidated Electronic

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.

Why Customize?

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.

Contact us today for more information about our overmolding capabilities.

The Ultimate Guide to USB Cables

In 1994, Compaq, DEC, IBM, Intel, Microsoft, NEC, and Nortel collaborated to develop the Universal Serial Bus (USB), a cable designed to standardize the connection between computers and peripheral devices such as keyboards, printers, network adapters, cameras, and storage equipment. USB was created to address usability issues [1], simplify software configurations, and permit greater data rates for external devices.

ultimate guide to usb cables

Shortly thereafter, in 1995, these same companies formed the USB Implementers Forum, Inc. (USB-IF) [2], a nonprofit organization created to support and facilitate the continuous advancement and adoption of USB technology and high-quality compatible USB devices.

In this post, we’ll be outlining the various advancements in USB technology over the years while exploring their impact on manufacturers and consumers alike.

USB Types

The original USB specification, introduced in the ’90s, defined connectors with data transfer rates of 1.5 megabits per second (Mbps) as low speed, while connectors with transfer rates of 12 Mbps were classified as full speed. Today there are three major types of USB connectors — USB Type A, USB Type B, and USB Type C, each which offer their own revisions and specifications depending on bandwidth needs.

Let’s first take a look at the different types of connectors available today.USB Types

usb type a cable

USB A-Type

Type A Type B USB

Considered the standard and most common type of connector, A-style connectors are found on the PC or charger side of most cables. This flat, rectangular interface joins directly to host devices and is held in place through friction. Durable enough for continuous connection but easy enough for users to connect and disconnect, this connector type is also available in micro variations.

usb type b cable

USB B-Type

Type-B USBs were traditionally used with printer cables but, with the advent of wireless printing, they’re now more often used in cell phones as Micro-USB B adapters; they’re also used in various peripheral devices [3] such as mobile printers and external hard drives. These USBs feature a square interface and are available as a Micro-USB B, USB Mini-b (5-pin), and USB Mini-b (4-pin).

usb type c cable

USB C-Type

USB Type C The newest type of connector on the market, Type-C is a one-size-fits-all solution. Featuring a reversible, symmetrical interface, this thinner, sleeker design is intended to replace older, larger USBs, though it can be adapted to support legacy connectors as well. Its small size allows all devices to easily adopt the single USB connector shape, eliminating the need for various types of cables.

USB Revisions and Specifications

USBs are further classified by their power specifications. Each version now features increased bandwidth, allowing for compatibility with a broader range of devices and applications.

USB 1.1

Though now obsolete, USB 1.1 or Full-Bandwidth USB was the first widely used consumer USB, allowing a maximum bandwidth of 12 Mbps for basic devices such as computer mice and keyboards.

USB 2.0

Also called the High-Speed USB, version 2.0’s main improvement was the upgrade to a bandwidth of 480 Mbps [4]; this allows for use in higher-bandwidth devices such as adapters, transfer cables, and mass storage equipment. USB 2.0 also offers backward compatibility to support USB 1.1 devices.

USB 3.0 aka USB 3.1 Gen 1

Dubbed the SuperSpeed USB, 3.0 further improves upon the 2.0’s bandwidth, jumping to a maximum of 4.8 Gbps with backward compatibility for legacy devices.

USB 3.1 aka USB 3.1 Gen 2

A key identifier of the latest USB 3.1 is the switch to blue connectors. Quickly gaining adoption in new products like the Apple MacBook, USB 3.1 Gen 2 is capable of transfer speeds up to 5 Gbps.

USB Power Delivery Standards

usb cable power delivery standards

Every USB advancement has offered enhanced power delivery standards and improved communication capabilities among devices.

USB 1.1 USB 2.0 USB 3.0 USB 3.1
Also Known As USB 3.1 Gen 1 USB 3.1 Gen 2
Release Date 1998 2000 2008 2013
Speed/Transfer Rate Full Speed

12 Mbit/s

High Speed

480 Mbit/s


5 Gbit/s


10 Gbit/s

Power N/A 5V, 1.8A 5V, 1.8A 20V, 5A
Max Cable Length 3 Meters (9’10”) 5 Meters (16’5”) 3 Meters (9’10”) 3 Meters (9’10”)

USB Type-C

As touched upon earlier, the most recent development in USBs, USB Type-C, is designed as a one-size-fits-all solution for data transfer and power supply on any device. Featuring a smaller connector, Type-C fits into one multi-use port to simultaneously charge devices and transfer data and also offers backward compatibility to support previous USB standards (2.0, 3.0, and 3.1).

USB Type-C 3.1’s reversible cable enables two-way power and data transfer, with 10 Gbit/s of bandwidth and power up to 20V at 5 Amps [6], or a total of 100 W — enough power to charge a laptop or provide 4K monitor resolution with one slim, streamlined cable.

A universal and nonproprietary technology, Type-C is quickly becoming the new standard for operating systems and hardware providers; Intel’s Thunderbolt recently switched to USB Type-C ports while enabling cross compatibility with USB 3.1, and Apple has announced that new MacBooks will feature a Type-C port [5]. In fact, USB-IF predicts that by 2019, all laptops, tablets, mobile phones, and other consumer electronics will be equipped with USB Type-C.

USB Cables From Consolidated Wire

For more than 100 years, Consolidated Electronic Wire & Cable has been delivering high-quality wire and cable solutions to countless markets and industries — at affordable prices. In addition to offering standard and custom products, our team can also create USB-C cables for all your charging and data transfer needs.

Watch the video!

For more information about our Type-C manufacturing capabilities or our full standard and custom molded cable selection, contact us today.


[1] http://www.eetimes.com/author.asp?section_id=14&doc_id=1285237
[2] http://www.usb.org/about
[3] http://www.webopedia.com/TERM/P/peripheral_device.html
[4] http://www.attinternetservice.com/resources/mbps-vs-mbps/
[5] https://www.macrumors.com/roundup/usb-c/
[6] http://science.howstuffworks.com/environmental/energy/question501.htm

Explore Consolidated’s Informative Technical Resources

At Consolidated Electronic Wire & Cable, we are committed to providing our customers with the resources they need to make an informed decision. On our website, we offer a variety of technical documents with information regarding NEMA configurations, color coding and insulation tips, and other wire and cable specific information.

  • Solid & Stranded AWG Chart: AWG-specification information for all outside diameter & wire types, including solid, concentric, rope bunched & more.PrintedCableJacketPortfolio-retouched
  • NEMA Configurations for Plugs & Receptacles: NEMA plug & receptacle configurations for voltage ranging from 125V to 600V, 15 to 60 amperes.
  • Color Coding Charts: Consolidated Electronic Wire & Cable’s color coding charts for various types of cable & wire products.
  • Wire Insulation Characteristics: A comparison of various types of wire insulation materials, including PVC, polyethylene, polypropylene, rubber, Neoprene, TPR & PEP.
  • NEMA Number Nomenclature: View the NEMA number nomenclature for plugs & receptacles, as well as current ratings & voltages.
  • Cable Standards Reference Guide: View the Cable Standards Reference Guide for NEC catalog reference information and a cable substitution chart.

We encourage you to visit the Technical Info area of our website to view these documents. We hope they prove to be of some use to you and that you find the information you are looking for.

View Our Technical Info Documents

The Advantages of Molded Cable Assemblies

Cabling is one of those components that people don’t often give much thought to, right? Need to power up something? Grab a cable, plug it in and go!

But, what if that cable poses risks to which you are unaware? Could the construction of that cabling system cause a weakness in the wiring?

molded-cable-assemblies-coverThe answers to these questions can be found in our new eBook, The Advantages of Molded Cable Assemblies. In this new resource, we provide you with information on how the protection of the terminal shells is an overlooked area that can be the difference between strong and weak cable assemblies.

Cable assemblies are highly engineered products made up of wiring, insulation, jacket, and terminals. As cable production and insulation has progressed over the years the safety of the wiring has improved tremendously. Intact cabling poses little risk of failure. The failures occur when the cables are cut and mated with a terminal. Choosing the right terminal end assembly is extremely important for all cable applications.

Terminal End and Cable Connectors

Let’s look more closely at terminal end options and the progression of cable connectors through the years. Realizing early on that joining exposed wires together was unsafe, the idea of a cable connector was born. Originally made out of porcelain or Bakelite, they were difficult to manufacture and expensive to replace.

Metal and plastic connectors prompted the replacement of these original multi-piece assemblies, and they became the standard until advancements in plastics and rubber forming led to molded cable connectors. These are the most commonly used connectors in today’s consumer electronics and appliances.
attaching cables together

Because there are many options available for connecting spliced cables together, you need to have the most comprehensive information to understand how important it is to choose the right connector. In this eBook you will find explanations of:

  • Terminal shell options
  • Non-molded components
  • Molded cable assemblies

At Consolidated, we want you to be safe and your products protected. Choosing the right cable connector is vital for all of today’s complex cable systems. With almost 100 years of delivering power through cabling, we want to pass on our extensive experience and knowledge to you.

Visit our site today to download your free copy of The Advantages of Molded Cable Assemblies, and learn how Consolidated can provide you with the molded cable assembly needed for your project.

Learn the Advantages of Molded Cable Assemblies

With Consolidated, it’s simple to create your own custom product.

While most of the modern gadgets we rely on appear wireless, behind the scenes things like smart phones, Wi-Fi, and tablets, require miles of wires and cable to operate. When it comes to supplying the perfect cables and wires for the modern digitized and online landscape, one-size definitely does not fit all.

Whether you are working with business machines, medical equipment, automation systems, computers, or telecommunications, you need custom designed and custom-built cables. At Consolidated Electronic Wire & Cable, thanks to our Create Your Custom Cable Now form, and our latest eBook, Creating a Custom Cable, it has never been easier to create a custom cable to match your unique needs.

New Online Form: Create Your Custom Cable Now

When you embark on your next custom wire and cable project, the best place to start is on Consolidated’s user-friendly website. There you will find our Create Your Custom Cable Now form. By completing this thorough but easy-to-navigate form, you are taking the first-step in our industry-leading custom cable production process. Other than general information, you will also be asked to supply details like:

  • Electric WireCable Type (Composite, Single or Multi Conductor, etc.)
  • Conductor (Number, AWG, Stranding)
  • Insulation Type
  • Shielding
  • Jacketing
  • Specification Demands

Once completed, just press the submit button. Soon after receiving your completed form, the experts at Consolidated will contact you directly. The best part of the form is that it gives us a solid idea about what you need, thus saving you both time and money.

In order to make filling out our Create Your Custom Cable Now even easier, we also offer a free eBook, Creating a Custom Cable to help guide you through the process.

New eBook: Creating a Custom Cable

Our new eBook, Creating a Custom Cable, gives customers an insider’s view of the design and production of custom cables. Some of the highlights of our eBook include:

  • Basic considerations such as cable length, cable size, environmental temperature, flexibility, and whether the cable will be used indoors or outdoors.
  • Deciding what kind of conductor is right for you, including bare, tinned, or silver plated copper wire.
  • Choosing a material to insulate your cables that will offer both performance and protection.
  • Other topics include shielding, jacketing, cable fillers, and critical standards.

If you are in the market for the highest quality custom cables, Consolidated Electronic Wire & Cable is your best choice. Both our Create Your Custom Cable Now form, and our eBook. Creating a Custom Cable, will help you start the process of creating the perfect custom cables to match both your specific application and your bottom line.

Important Discussion Points When Designing a Custom Cable Assembly

Custom-designed cable assemblies are an integral component of countless applications, including commercial and home electronics, appliances, medical equipment, aerospace, military, telecommunications, automotive, industrial equipment and more.

custom-cable-assembly-v2Designing a cable assembly can be difficult and challenging. Thankfully, a custom cable manufacturer can walk you through the process. However, be sure to address the items below with your manufacturer to ensure the final product meets your precise needs and exact application requirements:

  • Provide the manufacturer with full-scale drawings in a format that is well-recognized within the industry. If your drawing was created using unfamiliar software, the manufacturer may not be able to access the file and time will be wasted—which puts pertinent conversations about manufacturing and pricing on hold.
  • Schedule a design consultation with your manufacturer. They will have design experts on staff who can meet with you to ensure the job requirements are realistic and that your part can be successfully developed. For instance, discussing material options can be greatly beneficial, as design experts may know of a better, more suitable material for your part and application. Additionally, the right assistance can significantly reduce costs without affecting quality or performance.
  • Was your cable assembly designed and manufactured previously? Were you dissatisfied with the quality, timing or cost? If so, it is important that you communicate this to your wire and cable manufacturer. Understanding why the part or prior manufacturing process was deficient will make it easier to address and correct these matters.

Creating a custom cable assembly can be a challenging process, so don’t hesitate to ask a cable manufacturer for assistance. Through nearly a hundred years of service, Consolidated Electronic Wire & Cable has obtained extensive engineering expertise in custom cable assemblies for a wide range of applications.

Our state-of-the-art facilities, advanced manufacturing processes and staff of engineers and technicians, ensure that our customers receive the highest quality of products and services. You can learn more about our custom cable assembly capabilities here.

Start Your Custom Project With Us Today
Leave Us Feedback