Overmolded Cable Assemblies

What are Overmolded Cable Assemblies?

Custom overmolded cable assemblies are complete assemblies that seamlessly combine the various parts of the cable and connector to meet customer needs. The overmolding process involves injecting molten material into a mold cavity that, when cooled, conforms to the desired shape. In almost every sector and application, custom molded cable assemblies are widely used while being able to resist the rigors of the most challenging settings. Y.C. CABLE is a UL & ISO certified overmolded cable assembly manufacturer you can trust.

Differences between Molded Cables and Overmolded Cables

Molded cables and overmolded cables are both types of cable assemblies that feature a connector or termination at one or both ends of the cable. The key difference between the two lies in the manufacturing process and the resulting design.

A molded cable assembly is created by molding the cable and connector into one solid piece, typically using a hard plastic or rubber material. This process results in a cable assembly that is very durable and resistant to damage from external factors like moisture, dust, and physical stress. Molded cable assemblies are commonly used in applications where the cable will be exposed to harsh environments or frequent use, such as in industrial or military settings.

On the other hand, an overmolded cable assembly is created by molding a soft plastic or rubber material over an existing cable and connector. The overmold provides additional protection to the cable and connector, making the assembly more resistant to bending, twisting, and other forms of stress. Overmolded cable assemblies are often used in applications where flexibility is important, such as in robotics or medical devices.

Features  and Advantages of Overmolded Cable Assemblies

Y.C. Cable manufactures custom overmolded cable assemblies in a variety of circuit widths and cable lengths, offering durable strain relief at the connector-to-jacketed-cable contact.

• Reduces mechanical stress on wires and terminals due to overmolded strain relief

• Positive housing latching: Prevents unintentional disconnects

• Keep body terminals clean to avoid terminal damage during handling and mating.

• Provide a multitude of application possibilities with double-ended assemblies

• Various connector family options provide solutions based on size, current carrying capacity, wire style, or circuit-size requirements.

Our overmolded cable assemblies can provide assistance for critical power applications in some of the harshest environments, temperatures, chemicals, or medical locations.  We also assist customers to overcome mechanical durability requirements.  In addition, Y.C. CABLE has also been looking for the best alternatives to rugged wire harnesses, which allows us to continuously invest in the latest molding technology.  We can produce molded parts to quickly and cost-effectively seal and protect important connection points on equipment. Due to our superior cable product development skills, customers often seek our help in the initial design of new customized cable assemblies and wire harnesses products.

Overmolded Cable Assembly Materials:

> Polyethylene (PE)
> Polypropylene (PP)
> Polyvinyl Chloride (PVC)
> Thermoplastic Polyurethane (TPU)
> Acrylonitrile Butadiene Styrene (ABS)

Specified materials are available. Please contact our Sales Team.

UL & ISO Certified Cable Assembly Manufacturer in USA & China

Y.C. CABLE has comprehensive expertise in custom over-molding cable assemblies/one-piece cables and integration.  These products are commonly used in networking and communications, medical equipment, industry, automobiles, control panels, and control boxes. For continuous assurance, all our products are tested in compliance with industrial standards. Our factories in China have ISO 9001:2015, ISO 14001:2015, and ISO 13485:2016 certifications. We are also a member of the American Wire Harness Association and BICSI.

For off-the-shelf cables and accessories, please visit our online store: GRANDMAX.