Overmolded & Waterproof Cable Assemblies
Ruggedized strain relief and hermetic sealing for harsh outdoor and industrial environments. Featuring in-house mold design and rapid tooling.
SEAMLESS ENVIRONMENTAL ENCAPSULATION
Why Standard Backshells Fail, and Overmolding Succeeds
- Protection: IP67, IP68, and IP69K Waterproof Sealing
- Durability: Superior Strain Relief & Pull Strength
- Materials: PVC, TPU, PUR, and Medical Silicone
- Efficiency: In-House Tooling & Mold Design
Fast Turnaround: We design 3D CAD models and machine the steel/aluminum mold cavities in-house, reducing tooling lead times from months to weeks.
Custom Shapes: We can mold custom logos, specific ergonomic grips, or angled exits (45°, 90°) tailored to your enclosure constraints.
Prototyping: 3D printed sample molds available for physical fitment testing before cutting steel.
- PVC (Polyvinyl Chloride): Cost-effective, highly flexible, great for general outdoor use.
- TPU / PUR (Polyurethane): Exceptional abrasion resistance, perfect for heavy industrial and drag chain applications.
- TPE (Thermoplastic Elastomer): High flexibility in extreme cold temperatures.
- Silicone / LSR: Bio-compatible and sterilizable for medical applications, capable of withstanding extreme heat.
- IP Ratings: Guaranteed IP67 (dust and temporary immersion) up to IP68 / IP69K (continuous submersion and high-pressure washdown).
- Strain Relief: Engineered flex-relief tails prevent wire breakage at the critical connector junction during millions of bending cycles.
- Pull Force: The chemical bond between the cable jacket and overmold significantly increases the overall tensile strength of the assembly.
Frequently Asked Questions
Yes. We routinely design custom mold cavities to encapsulate standard connectors from brands like Molex, TE, JST, and Amphenol. This transforms a standard indoor connector into a rugged, waterproof IP67/IP68 interface.
Properly engineered overmolded cables typically achieve IP67 or IP68 ratings, making them suitable for prolonged underwater submersion. For agricultural or marine applications, we can even design to IP69K for high-pressure, high-temperature water jet resistance.
Absolutely. Since we cut the mold tooling in-house, integrating your corporate logo, part numbers, or specific ergonomic grip textures into the overmold design is a standard service we provide.
Yes. Unlike assembly-only shops, we have an in-house CNC tooling workshop. This drastically reduces tooling costs and shortens the lead time, giving us complete control over the quality and precision of the mold.
Tooling fabrication typically takes 2 to 3 weeks. Once the mold is approved, we can inject and deliver the first article inspection (FAI) prototypes within a few days.
Not at all. We utilize soft tooling (aluminum molds) or modular mold inserts for prototyping and low-volume production (HMLV). This keeps the NRE (Non-Recurring Engineering) tooling costs extremely low, making custom overmolding accessible even for smaller runs.
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