Plug Resistant M16 2 Pin 500mm Overmolded Cable Assembly

2pins Overmolded Cable Assemblies M16 Strip 500mm Aviation Plug Overmolded Wires

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Cable Assembly Overmoldering Process

The overmolding of a cable assembly is accomplished by forcing a material into a mold cavity under a great deal of pressure. For cable assemblies, the most popular materials used for an overmold are thermoplastic or thermoset materials. The injection molding machine, also known as a press, consists of a storage area for the mold resin. Sometimes it can be called a hopper. Delivery for the material is usually an injection ram or a screw-type plunger enclosed inside a metal tube also known as a barrel. Heating elements are installed into the barrel of the machine causing the mold resin to be heated to a molten state.

Overmolding has dramatically changed the appearance and functionality of cable assemblies over the last several decades. Through the utilization of the injection molding process, overmolding has allowed cable assemblies to have better functionality by:

Allowing them to become impervious to fluids, therefore being able to be exposed to harsher environments.

Providing them the ability to withstand shock, vibration, and continual flexing without damage to the termination point.

Making them more aesthetic by using tooling that allows for the inclusion of corporate logos and trade names as part on the overmold itself.

Through the use of 3D printing, models of the overmold can be quickly and cost effectively created to ensure that the overmold meet the application requirements prior to hard tooling.

Overmolding Design Considerations

When designing cable assemblies, engineers are using the overmolding process to provide strain or bend relief. This includes grommets as part of the assembly for any point(s) where an assembly needs to be installed through a housing/opening and as a covering for the connector backshells to protect the termination points and contacts. With the complexity of tooling increasing and the number of potential materials that can be used in the overmolding process expanding, any parts that are to be injection molded must be designed carefully.

FAQ:

Q: What are wiring harnesses used for?

A: Wiring harnesses are used in everything from remote control cars to jumbo jets. For example, the desktop computer you may be using currently has a myriad of different harnesses for data and power transfer, all to let you view a page like this one. Inside your vehicle are reams of cables, wires, terminals, and connectors that have to run through the entire vehicle in order to connect all the different components that allow you to simply drive from A to B. The harness itself sounds simple, but it can be rather complex when different connections, terminations, conductor sizes, sheathing, strain reliefs, and many other considerations have to come into play depending on the needs of the project. Our engineers design a complete system around the wires and cables needed to power electrical systems, transfer high speed data, and send and receive signals. If you’re ready to discuss your project’s unique requirements, talk over your options with a knowledgeable representative now.

Q: Are there different types of wiring harnesses?

A: The different types of wiring harnesses is only limited by your imagination. As we continue to increase our reliance on electrical systems powering even simply devices, the engineering inside of these applications requires custom made wiring and cable harnesses to complete the intended application. Each project requires its own custom set-up in order to be designed and manufactured to be able to effectively complete the task required of it. As you can imagine, this will be quite different for a remote control car versus a fighter jet, yet each require exact engineering design in order to function. From military applications, industrial, medical, telecommunications, and almost every industry in between, we design custom wire harness solutions that work.