Overmolded cable assemblies are critical components in many high-stakes industries where durability, robustness and functionality are key. At Amerline, we work with many different customers to create custom overmolded solutions that meet their exact needs.
Let’s dive into two standout examples that highlight successful applications of overmolded cable assemblies, as well as their value and versatility.
A unique application involved supporting law enforcement agencies with a tool designed to halt speeding vehicles. The product launches a net that wraps around the wheels of the moving vehicle, bringing it to a stop.
The product was so successful in police trials that the military grew interested. However, the original configuration was not robust enough for military requirements.
The solution? Overmolded cable assemblies. By incorporating Amerline’s rugged connectors and strain relief features from overmolding, the product could endure the harsh conditions faced by military teams. After rigorous military testing, the assembly proved successful. Full-scale production is pending further budget approvals.
This project demonstrates how overmolding can transform a standard product into a more robust, high-performance solution suitable for the most demanding of environments.
Another example of a successful application of overmolded cable assemblies comes from a client in the industrial cleaning sector that specializes in high-pressure water cleaning equipment.
The company needed to upgrade the assemblies for greater protection from environmental elements and for greater ease of use.
The solution required improving the seal on the back end of their connectors to prevent environmental ingress between the connectors and cables – especially when the cables were bent and flexed. Potting with an epoxy sealed the area where the wire terminates with the connector.
This sealant, combined with the strain relief provided by overmolding, created a watertight solution for long-term reliability even under challenging conditions. The added durability and user-friendly design of the custom cable assembly improved their cleaning systems’ overall functionality.
Overmolding provides added protection, durability and improved functionality essential for operations in harsh environments.
We use a low-pressure injection molding process to create our overmolded connector assemblies, bonding a durable material over the cable assembly. This results in seamlessly molded cable assemblies with high-quality material adhesion, providing enhanced performance, strain relief and robust protection in the field.
The cable overmolding process involves using a thermoplastic material that is injected into a mold cavity to encapsulate the backshell area of the connector in a cable assembly. A pre-mold can be applied to reinforce the outer shell, ensure proper cable alignment, and provide extra strain protection. Once the material solidifies, you get an aesthetically pleasing, injection-molded connector assembly that withstands even the harshest conditions, including UV exposure. We work with a range of materials that offer low-temperature flexibility, chemical resistance and the option for color coding to meet specific requirements.
At Amerline, we don’t just offer standard cable overmolding solutions – we tailor every project to meet the specific needs of your application. Our in-house team of experts works directly with you from the beginning, ensuring we understand your goals, whether it's adding strain relief, enhancing environmental sealing or designing for a unique fit.
Our overmolding solutions are designed to meet your unique challenges so you can deliver superior products.