Overmoulding is a transformative process in cable manufacturing, designed to enhance the performance, durability, and appearance of cable assemblies. At its core, overmoulding involves applying a secondary material, typically a thermoplastic, over an existing part – such as a cable or connector. This additional layer offers superior protection and functionality, ensuring cables can withstand demanding environments and applications.
The Overmoulding Process
The overmoulding process combines precision engineering and advanced material science. It typically involves two key stages:
- Insert Moulding: This initial stage involves the assembly of the cable and connector, which are carefully positioned into a mould cavity. Proper alignment is critical to ensure the quality and functionality of the final product.
- Overmoulding: The secondary material, often a thermoplastic, is heated to a molten state and injected into the mould cavity, encapsulating the cable assembly. As the material cools and solidifies, it forms a robust, protective layer that enhances the cable’s performance.
Precision control of temperature, pressure, and mould design is essential during this process to achieve consistent, high-quality results.
Benefits of Overmoulding
Overmoulding provides a wide range of benefits, making it a preferred solution for many industries.
- Enhanced Durability
The overmoulded layer acts as a shield, protecting the cable assembly from abrasion, impact, and harsh environmental conditions. This results in cables that are more resilient to wear and tear, reducing the need for frequent replacements. - Improved Strain Relief
By distributing and absorbing mechanical stress, overmoulding reduces strain on the cable and connector, prolonging the lifespan of the assembly and improving reliability in dynamic applications. - Environmental Resistance
Overmoulded cables are watertight and resistant to chemicals, UV rays, and extreme temperatures, making them suitable for challenging outdoor and industrial environments. - Customisation
The overmoulding process offers design flexibility, allowing for the inclusion of features such as ergonomic grips, seals, or grommets. It also enables the use of different colours and textures, improving both aesthetics and functionality. - Electrical and Signal Integrity
Overmoulding can enhance a cable’s electrical insulation and protect against signal interference, ensuring reliable performance in high-speed data transmission and other critical applications.
Materials Used in Overmoulding
Choosing the right material is vital to ensure the overmoulded cable meets specific application requirements. Common materials include:
Thermoplastic Rubber (TPR): Known for flexibility, durability, and resistance to chemicals and impact.
Polyvinyl Chloride (PVC): A cost-effective option offering excellent electrical insulation and resistance to oxidation.
Thermoplastic Elastomers (TPE): Ideal for outdoor applications due to their flexibility and environmental resistance, including protection against UV rays and ozone.
Each material offers unique advantages, and selection depends on factors like application environment, durability requirements, and cost considerations.
Applications of Overmoulding
Overmoulded cables are integral to a variety of industries:
- Medical: Providing safe, reliable connections for diagnostic equipment and surgical tools.
- Military: Ensuring robust performance in harsh and demanding conditions.
- Automotive: Enhancing the durability and reliability of vehicle wiring systems.
- Pharmaceutical: Supporting cleanliness and reliability in sterile environments.
- Agricultural: Offering weather-resistant solutions for outdoor machinery.
- Electric Vehicle (EV): Supporting innovative and sustainable transport systems.
Overmoulding at Cablepoint
At Cablepoint, we specialise in custom overmoulded and potted cable assemblies tailored to meet your specific needs. With over 30 years of expertise, we deliver exceptional quality, durability, and performance.
Why Choose Us?
- Customisation: Every cable assembly is built to your precise specifications.
- Sustainability: We actively reduce our environmental impact through sustainable practices.
- Fast Turnaround: We offer competitive lead times without compromising on quality.
- Global Reach: Based in Hull, UK, we serve clients worldwide.
Ready to elevate your cable assemblies?
Get in touch with our friendly, experienced team today to discuss your project.
Overmoulding is more than just a manufacturing technique – it’s a vital process that transforms cables into durable, reliable, and high-performing components suitable for the most demanding applications. Whether you need cables for military, medical, or industrial use, overmoulding ensures they’re built to last. Contact us today to learn more about our cable moulding capabilities
