What Is the Overmolding Process, and Why Is It Important?

What Is the Overmolding Process, and Why Is It Important?

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iCONN Systems offers custom-designed and application-specific connectors and cable assemblies, including overmolding. Our overmolding services ensure long-lasting, frequently pluggable cable assemblies that can endure substantial wear and tear. If you need branded or color-coded connectors, overmolding can be quite valuable to you.

Get in touch with iCONN Systems to learn how we can assist with your overmolding needs.

What Is Overmolding?

Overmolding is an injection molding process that combines two or more materials to form a single part. The process involves placing the cable assembly inside a mold, where a molten plastic material is injected into the mold cavity. This material encapsulates the junction between the connector and wire, forming a seamless, durable unit.

Benefits of Overmolded Cables

Overmolding provides numerous advantages, primarily in enhancing the lifespan and reliability of cable assemblies. Key benefits include:

• Increased flexibility at the cable exit
• Resistance to abrasion and shock
• Tamper-proof encapsulation of components
• 360-degree strain relief and pull strength
• Water-resistant or water-tight seals
• Improved quality and appearance
• Simplified installation
• Reduced human error

Customization Options

Overmolding allows for high levels of customization to meet specific application requirements. Customizable elements include:

• Overmold color for brand alignment or visual indication
• Logos or company names on the overmolding
• Flanges for attachment points
• Design shapes such as straight or right-angle exits
• LED indicators for easy identification of malfunctioning connectors
• Material choices like TPU, PVC, PP, PE, TPV, or ABS

Common Uses

Overmolded cable assemblies are suited for applications requiring durability against extreme conditions, including solar energy, military equipment, consumer electronics, medical equipment, and industrial/OEM uses.

Material Selection for Overmolding

Choosing the right overmolding material is critical. Factors to consider include the compatibility between the cable jacket and the molding material. Poor compatibility can result in thermal bonding issues. Common materials and their attributes are:

*Note: This chart is for general reference purposes only.

Designing Overmolding Tools

Designing overmold tooling is intricate and requires numerous considerations to minimize production costs and time. Thanks to advancements in prototyping, engineering teams can now 3D print tools to test their efficiency before final production.

Effective overmold design is essential for ensuring quality and functionality. The process begins with advanced computer software for designing mold details and prototypes. Depending on production volume needs, molds can feature single or multiple cavities.

Technological Tools in Overmolding

Aluminum Tooling

• Best for low-volume production
• Supports over 10,000 parts
• Inexpensive with good heat dissipation

Steel Tooling

• Best for high-volume production
• Supports intricate designs
• More finishing options

3D Printed Tooling

• Used for prototyping
• Cost-effective
• Limited to 50-100 mold cycles

MoldFlow Software

This specialized software simulates tooling designs to identify and correct potential flaws, ensuring quality and cost efficiency before actual production begins.

Prototyping for Overmolding

Prototyping is essential when designing for high-volume, multi-cavity tooling. 3D printed prototypes allow for rapid, risk-free testing and adjustment, ensuring the final product meets all design and performance standards.

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Technologies: Overmolding, Injection Molding, and Insert Molding

Injection Molding

Injection molding creates solid pieces by shooting molten plastic into a mold, using high pressure for material adhesion as it cools.

Insert Molding

Insert molding permanently bonds two parts, typically used for placing inserts into molded parts or encasing electrical connections.

Two-Shot Molding

Cost-efficient for large production volumes, two-shot molding involves multiple materials being injected during a single mold cycle, ideal for multi-color or multi-material parts.

Common Myths About Overmolding Debunked

Some misconceptions about overmolding may deter companies from leveraging this effective process. Common myths include the extended response times, high costs, and perceived inflexibility of overmolded products. However, companies like iCONN Systems can dispel these myths by ensuring high performance, cost-effectiveness, and flexibility in overmolding applications.

Get in Touch with iCONN for Custom Overmolded Cables

iCONN Systems provides expert design engineering to create optimal cable assemblies tailored to specific application needs. Our capabilities include rapid prototyping, quality testing, and advanced planning, ensuring high-quality, efficient production. Contact us today to begin customizing your overmolded cable assembly!

Insert Molding & Overmolding

What is an insert molded tubing connector?

Insert molded tubing connectors eliminate manual assembly steps by directly molding connectors over an extruded component, achieving a strong polymer-to-polymer bond. This is ideal for complex multi-lumen assemblies.

What is overmolding?

Overmolding custom molds fittings or connectors over extruded tubes, streamlining the finishing of catheters or device assemblies.

Advantages of Insert Molding Connectors

Insert molded connectors offer molecular bonding with the tube, ensuring tight and reliable seals for gas and fluid connections.

Materials for Medical Tube Connectors

A variety of thermoplastics can be used, with considerations for bondability and physical properties.

Options for Insert Molding Connectors

Available forms include multi-port connectors, bifurcated/trifurcated junctions, T and Y configurations, barbed/threaded attachments, and manifold fittings.

Medical Devices Utilizing Insert Molded Connectors

These connectors are used in various medical device components, offering limitless shapes, sizes, and performance capabilities.

Why Choose Putnam for Medical Plastic Tubing Components?

With over 40 years of custom manufacturing experience, Putnam specializes in advanced extrusion and precision finishing, offering cost-efficient, high-performance medical tubing solutions.

Contact us to discuss how our expertise can benefit your project.

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