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Cable assemblies may use a series of protective sheaths, connectors and overmolding to protect electrical wires and terminations from environmental conditions. They are typically manufactured with application-specific connectors that ensure that the cables or wires can connect seamlessly with power sources, outlets and other electrical components and devices.
There are a number of reasons to shift from non-molded to molded cable assemblies. Typically, these applications would likely be more industrial or heavy-duty. Although they are frequently used in medical, consumer, and automotive assemblies. A molded assembly inserts an assembled connector and cable into a mold and injects the insulating and protective material around it. The plastic cools into a hardened case that provides an extra layer of protection, and integrates strain relief into a single unit. This ensures a more permanent connection that is more reliable than non-molded options.
In addition to providing excellent protection from harsh operating conditions, cable overmolding is more aesthetically pleasing than standard cable assemblies and can be tooled with company logos, trade names and colors for easy identification.
The 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.
Overmolded Cable Benefits
Overmolded cable assemblies are characterized by a protective layer of rubber or plastic molded around portions of the assembly. The primary benefits of overmolded cable assemblies include:
- Customization: You can customize the material, color, finish, and other physical properties of the overmold, which can help with product identification and branding.
- Durability and Flexibility: The outer layer of overmolded plastic or rubber provides additional support to cable and wire assemblies, particularly at connection points. This added support and protection reduces the potential for cable failure and extends the service life of the assembly.
Why Customize Overmolded Cable Assemblies?
Customizing your overmolded cable assemblies is the best option for ensuring your electronics are protected. They are ultimately more rugged and cost-effective. The overmolding process allows customization of the following:
- 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 standards including IPC/WHMA-A-620 and RoHS.
