Overmolding in the Custom Cable Assembly and Wire Harness manufacturing

What is cable overmold?

The process of cable overmolding integrates and seals a wire with a connector, resulting in the creation of a single unified component. The incorporation of over-molding enhances strength, quality, and protection, making it an optimal technique for cable production across various industries. The process of over-molding is a great way to protect cable assemblies and connectors from tough environments. Whether it's for medical purposes that require sterilization or connectors that need strong strain relief, we've got the perfect solution.

The Cable Assembly Overmolding process begins with a soldered cable and PCB, or crimped terminal wire inserted into the housing. The unmolded cable is carefully inserted into the meticulously crafted tool or moldset, ensuring that the cable remains securely positioned. Subsequently, the mold set is closed and filled with the appropriate low-pressure molding material like PVC, or TPU, resulting in an all-in-one sealed component where strain relief is directly adhered to the cable.

What is Cable Strain relief?

Strain relief, also called SR, refers to a cable gland, which is specifically designed to alleviate the strain or stress exerted on electrical cables. These parts are intended to be placed over electrical cables to safeguard them against damage caused by excessive tension.

A strain relief or cable gland can protect the wires and cables by securing the power cord to the electrical equipment panel. It helps prevent stress and damage as it passes through the equipment panel. Although it doesn't relieve strain on the cable when it exits the equipment, it does alleviate strain on the electrical connection and circuitry inside. The term "strain relief" is commonly used in North America, while "cable gland" is more commonly used in Europe and other parts of the world.

 Cable Overmold Cavity Designs

The number of cavities of the overmolding depends on the size of the product, as well as the tonnage of the molding machine, the same tonnage of the molding machine, the smaller the size of the product, the more the number of cavities formed at a time, the smaller the vice versa, if the tonnage of the molding machine is large enough, you can open a large enough mold according to the production demand, the more the number of a single production, the higher the efficiency. Of course, the larger the mold, the greater the pressure required, if the machine tonnage is not enough, it easily leads to the lack of overmolding resin.

Cable Overmolding Materials

We offer over-molded cables made from a wide range of thermoplastic materials. Our overmolded cables come in different colors and shapes, just like any other regular cable. Plus, these cables are much stronger than common ones. Some of the materials we provide include:

• PVC: Polyvinyl chloride or PVC is possibly the most widely used thermoplastic for overmolding. It's an amorphous material that some people consider controversial. But don't worry, our PVC cables have a soft, rubber-like feel and excellent flexibility. The hardness of the materials is generally 45P, 60P, and 90P.
• TPU: Thermoplastic polyurethane is a great alternative to PVC. It's softer in texture and comes in more colors. TPU is also more pliable than PVC and can handle higher temperatures, making it more stable.

Applications

Overmolded solutions have become increasingly popular due to their exceptional durability and reliability. These innovative solutions are ideal for designing custom cable assemblies and wire harnesses that require superior protection against a wide range of environmental factors.

One of the critical benefits of over-molding is its ability to reinforce weak areas in an assembly, such as where wires are terminated with connectors, PCBs, or other electronic components. This reinforcement helps to prevent water ingress, shearing, shorting, abrasion, cutting, crushing, and tearing - all common issues that can compromise the integrity of an assembly.

In addition to providing enhanced protection against these types of threats, over-molding also offers many other advantages. For example, it can help improve the overall appearance and functionality of an assembly by creating a seamless finish that eliminates any unsightly gaps or exposed wires.

Furthermore, over-molded solutions are highly customizable and can be tailored to meet specific design requirements. This makes them ideal for use in various applications across various industries including automotive manufacturing, aerospace engineering, and medical device production.

Overall, if you're looking for a reliable solution for your custom cable assemblies or wire harnesses that provides unparalleled protection against environmental hazards while also enhancing their appearance and functionality - then look no further than over-molding!

Hooha Harness Custom overmold over 1000sets

Hooha Harness is a professional custom wire harness manufacturer based in China, renowned for its exceptional quality and reliability. With years of experience in the industry, we specialize in designing and producing top-of-the-line automotive wire harnesses that meet the highest standards of performance and durability.

Our team of skilled professionals has extensive knowledge and expertise in creating customized wire harness solutions to suit your specific needs. We use only the finest materials and cutting-edge technology to ensure that our products are not only functional but also aesthetically pleasing.

At Hooha Harness, we take pride in our ability to make all kinds of over-mold for the wire harnesses, and data cable. Our state-of-the-art facilities enable us to produce high-quality over-molds that provide superior protection against moisture, dust, heat, and other environmental factors.

Whether you need a simple or complex wire harness solution for your automotive application, we have got you covered. From design to production and delivery, we work closely with our clients every step of the way to ensure complete satisfaction.

Choose Hooha Harness as your trusted partner for all your custom wire harness needs today!