Overmolded Cable Assemblies and Molded Cable Assemblies

Computer cablesGalaxy is a leading U.S. manufacturer of overmolded cable assemblies, also called molded cable assemblies. An overmolded or molded cable assembly is a cable assembly that has an end or ends molded to create a sealed connector or plug. Overmolding or molding a cable assembly is often done to help improve the performance and durability of the assembly. The process of 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.

The most important consideration is the choice of compound used in the molding or overmolding process. It must adhere properly to the surface it is being applied to. Whether the cable being overmolded or 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 Molded Cable Assemblies

At 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 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.


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


FAQs about Overmolded Cable Assemblies and Molded Cable Assemblies

Can Galaxy provide UL ratings for 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 or overmolding?

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 or molded assembly.
Is there a minimum order quantity for 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.


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