Overmolded Cable Assemblies

homethumb-molded-cablesConsolidated Electronic Wire and Cable offers cable assemblies in a wide variety of customized styles. Cable assembles are designed to enhance operations and streamline systems in both commercial and consumer enterprises, and can be crafted via insert molding, overmolding, custom in-house tooling, or manual assembly.


Creating a custom cable ebookThe Advantages Of Molded Cable Assemblies

A cable’s failure point is often where the cable is cut and mated with a terminal. This is where the wires are exposed to the environment—and this exposure risks damage to the cable system, even in normal working conditions.

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molded-cable-assemblyWhat Is A Overmolded Cable Assembly?

Cable assemblies are critical to operations of all shapes and sizes: major military jobs and harsh environments, home electronics, medical systems and equipment, and automotive assemblies are just the beginning.

A overmolded cable assembly generally replaces an assembly that would otherwise rely on a backshell for protection and support. Available in nearly limitless shapes, sizes, materials, and configurations, overmolded cable assemblies are designed for extra protection against harsh conditions, demanding environments, abrasion, sterilization, and overall strain.


Creating a custom cable ebookLearn To Prevent Terminal End Risks

Our new guide, The Advantages of Molded Cable Assemblies, reviews the terminal shell options available to the cable industry, and the pros and cons of each type.

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Custom Overmolded Cable Assemblies

The process of molding utilizes molten PVC (polyvinyl chloride), as well as other high performance polymers, to encapsulate wiring materials and create endless products with a range of material, color, finish, and performance demands. These custom assemblies can be developed to fit specific junctions, encapsulate particular objects, and provide focused relief to stressors and system challenges.

In addition to insert and overmolding, custom cables and assemblies can be crafted with:

  • Wire crimping and braiding
  • Ultrasonic welding
  • Cut and shrink tubing
  • Tinning and soldering
  • Tywrapping and lacing
  • In-line engineering

Standardized Overmolded Cable Assemblies

A diverse variety of industries call for overmolded cable assemblies to meet rugged performance demands, complex technical specifications, watertight compatibility, and superior strength requirements. Some of the most common standardized overmolded cable assembly applications include:

  • Medical Cables
  • Automotive Cable Assemblies
  • RF Cable
  • Patch Cord Assemblies
  • USB Cables
  • Video Cable Assemblies
  • HDMI Cables
  • Medical Market Components and PCB Encapsulation
  • SCSI, SAS & SATA Custom Cables
  • Environmentally Resistant Military Connectors
  • D-Sub Cables and Ferrites
  • Patch Cords with Boots, Strain Relief, and Flex Relief

High Performance, Custom Tooling

The strategic custom development of overmolded cable assemblies offers more than unique designs and creative configurations; by implementing high performance materials and expertly engineered interconnects, a overmolded cable assembly improves reliability, aesthetics, and overall environmental performance. Adaptable to nearly any situation, even those demanding watertightness or sterilization compatibility, overmolded cable assemblies offer a host of choices in:

  • Branding, including private labeling
  • Conductor materials and gauges
  • Custom color selections
  • Hardness requirements
  • Unique insulation materials
  • Specific dimensions

Overmolded cable assemblies can be engineered both with particular specifications and industry standards in mind. When working to configure the best solution, it’s important to also bear in mind industry standards and approvals, including:

  • IPC/WHMA-A-620C
  • Automotive J-1128
  • ISO 9001
  • UL
  • QS 900
  • NEC
  • RoHS Compliance
  • VDE
  • CE
  • OSHA
  • CSA
  • Category 5/6/7
  • C-UL
  • Lead Free
  • HAR

Molded Assemblies Capabilities

Cable Assembly Applications

Appliance Cable Assemblies
Audio/Video
Automotive
Battery
Braided Wire
Business Machines
Box Build
Camera Link
Coax & Coaxial
Coiled
Components
Composite Cable
Custom Molded Connectors
D-Sub Cables
Electromechanical
EMI/RFI Harness
RJ-45 (8-wire)
Flat Molded
Flat Ribbon
Harness & Molded Harness
HDMI & HDMI Mini Molded
IEEE Category 5 & Category 6
LED
Medical Wire
Miniature
Over-Molded Custom
Over-Molded D-Sub Cables with Ferrites
Patch Cords (with Boots/Strain Relief/Flex Relief)
RF Shielded
RFI Shielded
RJ-11 (4 and 6 wire)
RoHS Compliant
SCSI, SAS and SATA
USB (2.0)
USB (3.0)

Custom Capabilities

Copper Wire Braiding
Wire Crimping & Termination
Wire and Cable Prep
Cut & Shrink Tubing
Tywrapping & Lacing
Wire Product Identification
Tinning and Soldering
Ultra Sonic Welding
Cable Assembly Over-Molding
Insert Molding
In-Line

Manufacturing

Over-Molded Tooling
Assembly
Text Fixturing
PCB Insertion

Wire Termination Options

Molex Terminations
Amphenol Terminations
AMP Terminations
Circuit Board Ready
Spade Terminals
Fork Terminals
Ring Terminals
Hard Wired
LED
Light Sockets
Molded
Overmolded
Metal Formed
Plastic Injection Molding
Tinned
Soldered
Switches
Stripped and Tinned
Ultra Sonic Welding
Crimped Ends

Insulation Materials

PVC - Polyvinyl Chloride
SR-PVC - Semi Rigid Polyvinyl Chloride
Cellular Polyethylene
EPDM - Ethylene Propylene Diene Monomer
TPE/TPR - Thermoplastic Elastomers
PE - Polyethylene
LDPE - Low Density Polyethylene
HDPE - High Density Polyethylene
Cellular (Foam) Polyethylene
PU - Polyurethane
Polyurethane / Nylon
Low Smoke Plenum Co-Polymers / PVC
PP - Polypropylene
Cellular (Foam) Polypropylene
FEP - Fluorinated Ethylene Propylene
TFE - Tetrafluoroethylene
PTFE - Polytetrafluoroethylene
ETFE Tefzel
PVDF Kynar
ECTFE Halar
IRR/PVC - Irradiated Polyvinyl Chloride
XLPE - Cross-Linked Polyethylene
Vinyl (PVC)
And many others

Conductor Materials

Bare Copper Wire
Tinned Copper Wire
Silver Plated Copper Wire
Nickel Plated Copper Wire
Copperweld/Copper Covered Steel

Voltage

Up to 600 V (UL)
3000 V (Military)

Temperature Range

-65ºC to 250ºC

Conductor Gauge

4 to 40 AWG

Conductor Cabling

1 Conductor to 60 pairs

Stranding Constructions

Solid
Bunched
True Concentric
Rope Lay

Conductor Coatings

Tinned Copper
Heavy Tinned Copper
Prefused Copper
Overcoat Copper
Top Coated Copper
Silver Plated Copper
Nickel Plated Copper

Shielding

Braided Wire
EMI/RFI Shielding
Mylar/Aluminum Foil
Mylar/Aluminum Foil + Braid
Spiral Serve Wire

Cable Filler

Polypropylene
Nylon
Paper

Quality Assurance

Consolidated Total Quality Mangement

Quality Control

Single Point Accountability

Testing

Standard UL, CSA & Industry Testing Procedures
Custom Testing Parameters Available Upon Request

Production Volume

100 Units to OEM Volumes

Typical Lead Time

3 Weeks to 10 Weeks

Additional Information

Industry Focus

Aerospace
Agriculture
Amusement
Appliances
Automotive
Broadcast
Commercial
Communications
Computer
Factory Automation
Gaming
Home Entertainment
Local Utilities
Marine
Medical
Military
Power Supply
Public Safety & Transportation
Renewable Energy
Robotics
Security
Solar Power Energy
Telecommunications
Wind Power Energy
Wireless
Industrial Machinery

Industry Standards & Approvals

ISO 9001
QS 9000
RoHS Compliant
CE
CSA
C-UL
HAR
Automotive J-1128
UL
NEC
VDE
OSHA
Category 5/6/7
Lead Free

File Formats

CAD Capabilities
DWG
PDF
.PPT
.XLS/.XLSX
.DOC/.DOCX