Many standard cable assemblies have over-molded connectors, such as printer and electrical cord sets. If a cable assembly and its connector have worn out, one can perform over-molding. It acts as a secure seal for the cable assembly and the connector. Over-molding provides mechanical strength to the cable assembly and connector, allowing them to withstand extreme environmental conditions.
An Overmolded Connector is built using an injection molding process that combines two or more materials with a molded plastic component over them to create a single part. These connectors are designed to protect critical components from environmental impacts. Today, the cable assemblies manufacturer provides custom electrical connector over molding capabilities to meet the needs of various industries, including automotive, consumer electronics, and medical manufacturing. Work with a cable assemblies manufacturer with the expertise to provide an ideal Overmolded connector at the best quality and cost.
Why is Over Molding Technology Important?
Over moulding, or insert moulding, is a process in which two or more materials combine a wire harness and a connector to create a single part; to do this, the cable assembly is placed in a mold. Over moulding is classified into two types, i.e. insert moulding and multiple material moulding . One can customize the shape of the mould, its colour, its material, and any markings, such as an engraved logo.
The most common over-molding applications include solar energy, military equipment, consumer electronics, medical equipment and industrial/OEM applications. Overmolding has many benefits over the traditional assembly processes like better adhesion between components, more compact design, lower labour costs during production, noise and vibration reduction, protection from UV and corrosive chemicals, waterproofing and electrical insulation.
Reasons to Use an Overmolded Connector
Connectors are essential components of any electronic system. They allow connecting wires, cables, devices, and equipment reliably and safely. An Overmolded Connector offer significant opportunity for improved shock absorbency, pull strength, and strain & flex relief, staying in service longer. These connectors are more durable and reliable than traditional connectors; therefore, they are ideal for extreme weather. They are perfect in washdowns, constant sanitation, and frequent underwater and above-water strain applications.
Also, overmolding provides a versatile solution for producing connectors, as manufacturers can create a wide range of components with different shapes, sizes, and functions to meet the requirements of their customers. One can also have customized over-molded cable connectors to have the form and inscriptions as required. One can also customize the mechanical properties of the connector, like increasing flexibility, resistance, and every other element.
The trend is moving from manual assembly to over-moulded connectivity, especially in the agricultural sector and vehicles with heavy daily loads and varying environmental conditions. Lastly, the main advantage of overmolding connectors is their longer life and higher reliability. It also shields the internal components, enhances protection and helps cable assemblies last in the harshest environments.
Critical considerations for selecting the right over-molded connector
When choosing an over-molded connector, there are several factors to keep in mind to ensure optimal system performance. Factors like temperature, moisture, dust, and vibration can affect the connector’s performance; hence, first consider the environment in which one will use the connector. Selecting an over-molded connector that can withstand these environmental conditions is crucial to maintaining reliable and efficient system performance.
Next, choose an over-molded connector that aligns with the data transmission requirements of the specific application, as some connectors are designed for high-frequency applications. In contrast, others are better suited for lower-frequency applications. One should also consider the number and type of connections, as the connector must possess the appropriate number and type of contacts to support the data transmission needs of the application.
Next, the size and shape of connectors depend on the physical dimensions and requirements of the wires, cables, devices, and equipment. Hence, ensure that the connectors match the size and shape of the corresponding parts. Next, choose the Overmolded connector with high protection or sealing to protect the system from external hazards such as dust, water, vibration, shock, or interference. Lastly, approach the cable assemblies manufacturer who delivers various kinds of best quality cable assemblies and relevant types of connectors needed for the application.