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Cable overmolding is a manufacturing process that combines and seals a wire with a connector resulting in a single unified part. The added strength, quality, and protection overmolding provides makes it an ideal method of cable production across all industries.The injection molding process is a key factor in cable overmolding as it allows the machinery to accurately control the critical tolerances to the external temperature and pressure. Continuously controlled hot melt thermoplastic is used for overmolding to provide a consistent design and to maintain the right balance between rigidity and flexing of the cable and the cable housing.
During the manufacturing process, the material is molded over the cable/wires while the cable is being inserted into an insulated or non-insulated raceway or connector.
Differences between Molded Cables and Overmolded Cables
| Molded Cables | 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. |
| Overmolded Cables | 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. |
Cable Overmolding Materials:
SAISONIC offers over-molded cables fashioned from a wide range of thermoplastic materials. Our overmolded cables come in different colors and shapes, which are essentially the same as any other traditional cable. Moreover, the strength of these cables is far superior to the strength offered by common cables. Some of the materials we offer include:
1> Polyethylene (PE)
2> Polypropylene (PP)
3> Polyvinyl Chloride (PVC)
4> Thermoplastic Polyurethane (TPU)
5> Acrylonitrile Butadiene Styrene (ABS)
SAISONIC Custom Cable Assembly Service
Since 1992, SAISONIC has manufactured custom cable assemblies to meet the exact specifications of our customers in a myriad of applications and industries. We create a precise custom cable assembly or wire harness to perfectly meet the demands of our clients' advanced electronic equipment. SAISONIC has been a leader in the custom cable assembly industry for several decades and creates entirely custom cable assemblies and wire harnesses for every industry imaginable.
In these cases you may need a custom cable assembly
1. Connector, wire is a non-standard cable assembly,
2. The cable assembly does not meet your expectations
3. You need to create a prototype to test the design concept of your cable assembly
4. A wide range of insulations materials
5. A plethora of wrapping and shielding options
6.Cable assemblies with special material characteristics
7.Length, shape, color need to be customized cable assembly
8.Custom conductor sizes
9.Options for filler material
10.Choice of jacket materials
SAISONIC's cable assembly and wiring harness customization services include:
.Cable and wire harness cutting .Cable and wire harness stripping
.Cable and wire harness terminating .Cable and wire harness splicing
.Cable and wire harness bending .Cable and wire harness ultrasonic welding
.Cable and wire harness soldering .Multi-conductor, ribbon cable, coaxial and phone cable processing
.Cable and wire harness potting .Cable and wire harness tying
.Cable and wire harness taping .Cable and wire harness sleeving
.Cable and wire harness tubing
We can provide OEM and ODM services according to customers' needs. wire harness and cable assembly can be widely used in UAV, medical, automotive,automation equipment, power, industrial equipment, home appliances and consumer electronics industries and exports to the United States, Europe, Japan, South Korea and other countries and regions.
Contact SAISONIC for Turnkey Custom cable assembly Solutions
If you have any questions, please contact us and we look forward to hearing from you. We have long experience in manufacturing wiring harness assemblies and cable assemblies for various industries
Q: Are you a trading company or a manufacturer?
A: We are a factory. 33 years of experience in the manufacture of wiring harnesses and cable assemblies since 1992.
Q: What is your lead time?
A: Usually 5-10 days if it is in stock. Or 15-20 days if there is no stock, it is determined according to the quantity.
Q: Do you provide samples? Is it free or extra?
A: Yes, we can provide samples free of charge,Prototype sample excepted.
Q:What are your terms of payment?
A: Payment <= $2000, 100% in advance. Payment >= USD 2000, 30% wire transfer in advance, balance paid before shipment.
Q:How is your quality assurance implemented
A:We have obtained ISO9001 / ISO14001 / ISO13485/ISO45001 and IATF16949 certification, we started take the traceability of incoming material quality management policy, the whole process of harmful material management. Comply with ROHS,REACH and other regulations.
Why choose us?
1. Advanced process equipment
2. Competitive price and high quality
3. Excellent after-sale service
4. Attractive design and various styles
5. Strict quality assurance system and perfect testing means
6. Advanced process equipment
7. Delivery on time
8. Have a good reputation in the domestic and overseas.
The company's products have passed China 3C, the United States UL, Germany VDE, Australia SAA, EU CE and other quality and safety certification. And meet the environmental requirements of RoHS and Reach; At the same time, the management system has passed the ISO 9001:2015, ISO14001, ISO13485, ISO45001 and IATF16949 certification, also has obtained the SONY Green partner certification issued by the SONY company. Due to the strict quality control system and good customer service team, our wiring harness components and cable components sell well all over the country, and exported to many countries and regions, deeply trusted by users.
"Customer satisfaction" is the company has always adhered to and implemented the policy. We sincerely hope to work together with customers and friends all over the world to develop together and create a better tomorrow.
