Overmolded Cable Assemblies
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SAISONIC provides custom overmolding for OEM cable assembly projects across a wide range of market sectors and is equipped with 22 molding machines. The process can be used to encapsulate connectors, cable joints, circuit boards, switches, and other components to improve protection and extend service life in demanding applications.
Overmolded cable assemblies are cable and connector assemblies protected by a molded layer around the connector body, termination area, or strain relief section. This molding process helps protect against dust, moisture, bending, pulling, and vibration while creating a clean, integrated cable structure.
Manufacturing Process
- Cable Cutting
- Wire Stripping
- Soldering or Termination
- Inner Molding
- Outer Molding
- Swing / Bending Test
- Continuity and Hi-Pot Testing
- Packaging
Custom Overmolded Cable Assembly Options
- Single or dual ferrite cores
- Transition molds, including T-mold and Y-mold designs
- Audio connectors, including banana plug jacks, DC power plug jacks, and 3.5 mm stereo plugs
- Molded strain relief
- Circular connectors, including M8 and M12 cable assemblies
- Right-angle molded assemblies
- Additional accessories such as grommets, backshells, fuses, and other assembly components
- Encapsulation processes, including low-pressure molding, potting, and protective coating for circuit boards, connectors, switches, and enclosures
- Custom logo or company name molded onto the cable assembly for product identification and branding
Available Encapsulation Materials
- PVC (Polyvinyl Chloride)
- TPE (Thermoplastic Elastomer)
- LCP (Liquid Crystal Polymer)
- TPV (Thermoplastic Vulcanizate)
- TPR (Thermoplastic Rubber)
Examples of Custom Overmolded Cable Assembly
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USB Type-C Charging Cable -
CAN Bus Cable Assembly -
Camera Cable Assembly -
HDMI Cable Assembly -
Custom Molded Cable Assembly -
Computer Cable Assembly -
Appliance Cable Assembly -
Office Automation Cable Assembly -
Drone Cable Assembly -
Automotive Cable Assembly
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