Overmolded Cable Assemblies

What Are Overmolded Cable Assemblies?

Cable assemblies are collections of specific cables, wires, and connectors assembled for a specific application, such as an appliance, computer, or machine. Overmolded cable assemblies are covered with a layer of polyurethane resin that holds the cables together and provides protection against moisture, vibration, and other hazards that could impair long-term performance. The assembled cables and wires are placed in a special injection mold, then molten resin is pumped inside, completely encasing the cables. Once cured, the resin coating is permanent.

Benefits and Uses of Overmolded Cable Assemblies

Flux Connectivity develops standard and custom overmolded cable assemblies for products and equipment used in everything from laboratories and data centers to home consumer electronics. All of our assemblies meet or exceed IPC/WHMA-A-620 standards.

The benefits of choosing overmolded cable assemblies include:

• Versatility and complete customization. We offer a comprehensive selection of wires, cables, terminations, and connectors compatible with different conductive capacities. Choose from a range of Pantone colors and thermoplastics to align with your project requirements.
• Durability that lasts. Overmolding binds the assembly snugly for a secure, precise fit. Our resins protect against moisture ingress, corrosion, dust, and chemicals. In addition to many industrial and consumer-grade applications, overmolded assemblies are well-suited to use in outdoor or mobile environments.
• Strain and internal breakage protection. The protective resin layer reduces abrasion and wear and tear on the exterior, and keeps internal wires and cables from shifting or abrading inside the assembly. The resin layer is also thick enough to mitigate damage to individual cables or wires caused by bending or twisting, and protects the ends of the assembly from damage from pulling.
• Simplified, accurate installation. Overmolding creates a pre-packed unit of cables and wires that cannot be separated or tampered with, so there is no risk of missing or incorrect components during installation. Because many colors are available, it’s also possible to color code assemblies as a visual aid for installers, or simply to add an aesthetic touch to products.

Applications for Overmolded Cable Assemblies

At Flux Connectivity, we offer many options for optimizing overmolded cable assemblies to application requirements. Some examples include:

• Waterproof resins for medical or food production settings because cables can be sanitized or sterilized without damaging the components inside.
• Cables for home entertainment systems outfitted with specific fittings and trimmed to length for easy connections.
• Weather and temperature resistant cables for aerospace machinery.
• Heavy-duty protection for cables in industrial automation and robotic systems.
• Military- and defense-grade resins that are protective and matched to equipment colors.

Proprietary FluxForce polyurethane resins block exposure to water, oil, and heat, offering temperature protection from -40°C to 90°C. Once set, the resins resist UV radiation and flame damage.

Contact Flux Connectivity for Overmolded Cable Assemblies

Flux Connectivity is an innovative force in contract manufacturing, providing high-quality overmolded cable assemblies that are durable and protective for virtually any application. Our services also include engineering and product development support, custom kitting and electrical assembly, integrated supply chain and inventory management, and user-friendly MRP solutions.

Contact us today to discuss your cable assembly needs or to request a quote.