Custom Overmolded Cable Assemblies
Where innovation meets reliability! Our cable assemblies are meticulously crafted to meet your unique specifications, ensuring seamless connectivity and superior performance. With our expertise in overmolding techniques, we bring you a solution that enhances durability and provides added protection against harsh environments, mechanical stress, and moisture.
Whether it's for industrial applications, automotive systems, or specialized electronic devices, Custom Wire Industries has the capability and experience to create a custom overmold for any assembly. Experience the power of tailored solutions that redefine connectivity standards.
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What are Molded Cable Assemblies
Molded cable assemblies are cables with a molded connector at one or both ends. The molding process involves encasing the cable and connector in a protective and durable material, typically a thermoplastic or thermoset material such as PVC (Polyvinyl Chloride) or TPE (Thermoplastic Elastomer).
The purpose of molding cable assemblies is to provide additional protection to the cable and connector, making them resistant to environmental factors such as moisture, dust and mechanical stress. The molding process prevents the cable from being pulled or twisted at the point where it connects to the connector, reducing the risk of damage and ensuring a more secure connection.
Molded cable assemblies are commonly used in various applications, including consumer electronics, automotive, industrial equipment, medical devices and telecommunications.
Custom Overmolded Wire Assemblies for Enhanced Performance
We specialize in providing custom overmolded wire assemblies tailored to meet your specific needs. The concept is similar to overmolded cable assemblies except that wire assemblies focus on individual wires, while custom over-molded cable assemblies encompass a complete cable system. We provide added protection to your individual wires, offering resistance against moisture, chemicals, and physical damage. With our advanced cable assembly and manufacturing capabilities, we offer a wide range of customization options to ensure a perfect fit for your application.
Types of Molded Products
Some of our most common custom molded cable assembly products include, but are not limited to:
- Modular plugs and jacks
- Printed circuit connectors
- Circular style connectors
- Audio and video-style connectors
- Coaxial plugs
- Rectangular rack and panel connectors
- Specialty connectors
Modular Connectors
Modular plugs and jacks are most commonly used for telephone wiring and Ethernet cables. There are many different types of modular connector overmolds we can manufacture including 8P8C, 6P6C, 6P4C, and 4P4C plugs and jacks.
Printed Circuit Board Connector (PCB)
A printed circuit board, or PCB, connector is typically used in electronic devices like computers. Some of the PCB connectors we use for overmolding include back panel connectors, board and wire mount plugs and sockets, power jacks, and memory and PCMCIA connectors.
CPC Style Connectors
Circular plastic connectors (CPC style connectors) are ideal for a wide variety of applications including medical equipment, industrial machinery, instrumentation equipment, robotics, vehicles, agricultural and welding equipment, lighting, and HVAC.
Audio and Video Style Connectors
Audio and video connectors are electrical or optical connectors used for carrying audio or visual signals. These connectors are often used for computers, radio, and telecommunication industries. There are many different types of audio-only, video-only, and audio/video connectors. Some of the connectors we have include coaxial RCA jacks, optical TOSLINK connectors, 3.5mm TRS mini-jacks, DVI connectors, and HDMI connectors.
Coaxial Plugs
Coaxial connectors are often used for wiring in broadcasting for radio communication, home video, and cable television equipment. Some more specialized coaxial cable connectors are used in US Navy ships, underground conduits, elevator shafts, and telemetry applications.
Rectangular Rack and Panel Connectors
Rectangular rack and panel connectors are generally used for data, power, and signal applications. These connectors can be manufactured with 45°, 90°, and 180° cable exits to perfectly fit your application.
Specialty Connectors
Custom Wire Industries also supplies specialty connectors for a wide variety of unique applications in need of specific connections. If a typical connector won’t work for your application, get in touch with our electromechanical engineers for a completely customized solution.
Why Customize Overmolded Cable Assemblies?
Customizing overmolded cable assemblies offers several benefits and advantages, including:
- Enhanced Protection
- Strain Relief
- Design Flexiblity
- Improved Cable Management
- Branding and Identification
Electromechanical Assemblies Tailored to Your Industry
From assemblies that must withstand harsh environments, like extreme heat or cold, to high-performance cables our team of electromechanical engineers can take your cable assembly designs from prototype to completion.
Custom Wire Industries has the engineering, technology and facility to accommodate any electrical overmolding requests, whether it's connectors, splices or power transmission assemblies. Overmolding provides increased protection against liquids, heat, cold, and impact. We can design a custom electromechanical component for nearly any industry, from agriculture to medicine.
Contact our electromechanical engineers for custom overmolding for wires. Custom Wire Industries, Inc. is a UL and CSA certified electrical wire and cable assemblies manufacturer. We regularly serve the cities of Indianapolis, Detroit, Chicago, Minneapolis, Denver, Atlanta and Dallas.
Wire and Cable Assemblies |
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| Coaxial Cable | Electronic Kit | Fiber Optic Cable | ||
| Mechanical Cable | Medical Cable | Power Cable | ||
| Electrical Assemblies | Wire Assemblies | Kit Assemblies | ||
| Industrial | Lead Wire | Wire Harness | ||
| Cable Assemblies | Overmolded Assemblies | |||