Overmolded / Molded Cable Assemblies

Galaxy is a leading U.S. manufacturer of overmolded cable assemblies, also called molded cable assemblies or injection molded assemblies.

Overmolded, Molded, and Injection Molded Cable Assemblies

White D-Sub overmolded cablesGalaxy is a leading U.S. manufacturer of overmolded cable assemblies, also called molded cable assemblies or injection molded cable assemblies. An overmolded/injection molded/molded cable assembly is a cable assembly that has an end or ends molded to create a sealed connector or plug. Overmolding, injection molding, or molding a cable assembly is often done to help improve the performance and durability of the assembly. The process of molding, injection molding or overmolding can be done in many different ways using a variety of different compounds depending on the physical, mechanical and electrical requirements of the end product.

Black D-Sub overmolded cablesThe most important consideration is the choice of compound used in the molding/injection molding/overmolding process. It must adhere properly to the surface it is being applied to. Whether the cable being overmolded or injection molded is PVC, Teflon®, silicone, or thermoplastic material, it is imperative that the correct compound is chosen to ensure a structurally sound finished product.

Galaxy works with customers from the design and prototype phase of a project all the way through large production runs. With low minimum order requirements and engineering design services available, Galaxy is ready to meet specific overmolded cable assembly needs.

The Galaxy Differentiator for Overmolded or Injection Molded Cable Assemblies

Galaxy Mini-Jector 55PAt its core, Galaxy is a company that has extensive wire and cable expertise. That expertise allows Galaxy to look at a customer’s drawing or specification sheet and identify areas of significant cost savings with regards to the wire or cable selection to be used in an overmolded, injection molded or molded cable assembly. Having a complete understanding of the many different types of wire and cable compounds available, Galaxy’s engineers can properly assist in finding the right overmold or mold compound that will work for a specific application. Making certain that the completed overmolded or molded assembly will work as designed – both electronically and mechanically – requires a full understanding of the physical environment as well as the intended use of the end product. With all these factors in mind, Galaxy can help in choosing the correct compounds that are necessary.

Galaxy has on-site equipment – a Mini-Jector Model 55P – that allows for the manufacturing of overmolded or injection molded assemblies to be produced in our facility. The advantages of having in-house overmolding are that Galaxy is now vertically integrated and can control the entire cable assembly process to ensure that the quality of the finished product meets our high standards.

Injection Molded and Overmolded Cable Assembly Technical Capabilities

Galaxy has ability to offer a broad range of overmolded cable assemblies and molded cable assemblies to customers.  From standard cord sets and extension cords to unique connectors that need to be made for a specific application, Galaxy has the experience and resources to help.  Galaxy’s Quality Control Department has the experience and testing equipment to perform both physical and electrical testing to ensure that products are manufactured correctly and function as designed.

Common Overmold and Mold Compounds

*Teflon® is a registered trademark of E. I. du Pont de Nemours and Company

Quality Control Processes at Galaxy Wire & Cable

Galaxy Wire & Cable ensures the highest quality design and construction throughout its entire process via rigorous and thorough quality control (QC) processes. Here’s a behind-the-scenes look at Galaxy’s QC process from start to finish, including the manufacturing of overmolded cable assemblies / molded cable assemblies / injection molded cable assemblies.

FAQs about Overmolded Cable Assemblies and Molded Cable Assemblies

Can Galaxy provide UL ratings for molded, injection molded or overmolded products?

Yes, Galaxy can produce and provide UL rated products as long as all of the material used is UL approved. If there is uncertainty about the need for UL ratings, please contact Galaxy to discuss.

Is using epoxy or potting compound the same as molding, overmolding or injection molding?

No, epoxy or potting compounds are applied to an assembly and must cure over time. Epoxy or potting compounds are commonly used to environmentally seal a connector or backshell. Molding or overmolding a product does not always ensure that it will be environmentally sealed.

What does Shore Hardness refer to?

Shore hardness is a durometer scale that refers to the hardness of a compound. That compound could be a form of plastic or rubber, among many other materials. The Shore hardness information is often an important consideration when designing an overmolded/molded/injection molded assembly.

Is there a minimum order quantity for injection molded, molded or overmolded cable assemblies?

No, there is no minimum order required. However, if this is a custom application then there would be tooling charges. These charges can be discussed during the design and quoting process.

Contact Galaxy Wire & Cable for Overmolded Cable Assemblies and Molded Cable Assemblies

Contact Galaxy for further assistance with molded or overmolded cable assemblies.