Overmolded Cable Assembly
Sealed, strain-relieved — molded-in for life.
注塑过模一体成型的应力减除 + 密封一体化电缆组件。硅胶 / TPU / PVC 过模料，IP67/IP68 密封，拉脱力 > 180 N。
- Sealed
- IP68
- Pull force
- 180 N+
- Overmold
- TPU·Si
- From qty 1
- 0 MOQ
Overmold Materials
Four resins, four environments
Applications
Where overmold wins
- 消费电子手持设备 · 耳机 / 数据线
- 医疗器械延长线 · 可消毒
- 工业传感器 · IP67+ 户外
- 汽车 ADAS 线束 · 油污环境
- 船舶 / 水下连接器
- 无人机 / 机器人动态线
Overmold Capability
Published spec
| Materials | |
| Overmold options | PVC · TPU · Silicone · TPE |
|---|---|
| Durometer | 50A – 95A (Shore A) |
| Cable range | |
| Cable diameter | 2.5 – 12 mm |
| Wire gauge | 32 AWG – 10 AWG |
| Conductor count | 2 – 50 way |
| Mechanical | |
| Pull force | ≥ 180 N (per UL 486) |
| Bend radius | 5× cable ⌀ |
| Flex-life | 50,000 cycles @ 180° (per spec) |
| Sealing | |
| IP rating | IP65 / IP67 / IP68 / IP69K |
| Immersion | 1 m / 30 min (IP68) · hot water spray (IP69K) |
| Testing | |
| Pressure test | 100% on IP68 / IP69K lots |
| Continuity | 100% |
| Hipot | 500 – 3,000 V |
| Compliance | |
| Standards | UL 2238 · UL 62 · RoHS · REACH · USP Class VI (silicone) |
Frequently Asked Questions
Overmold FAQ
01Why overmold instead of a discrete boot + connector?
Overmolding encapsulates the termination in one molded shot — no secondary assembly, no glue joints to fail. Stronger strain relief, better seal, fewer parts to source. Higher tooling cost up-front but lower per-unit cost at scale.
02Can we overmold onto our existing connector?
Usually yes — we mold compatible TPU / PVC around most standard connectors (Molex, JST, Hirose). Free-issue connectors welcome. For tight IP68 we recommend overmold-compatible connector bodies.
03Tooling lead time & cost?
Aluminum tool (3 weeks): good for 50k – 100k shots. Hardened steel (5 weeks): 1M+ shots. Single-cavity tool ~$2,000 – $6,000 depending on geometry; we’ll quote with the DFM review.
04Minimum run size?
No MOQ once tool is amortized. First run can be as small as 50 – 100 pieces; we do short-run overmold without charging setup for repeat orders.
Ready when you are
Send your Gerber & BOM — get a quote in 24 hours.
NDA available · Free DFM review · Senior engineer response.