Overmolded Cable Assemblies for
Industrial, Medical, and High-Vibration Applications

Each mold cavity is manufactured from 7075 aluminum or hardened P20 steel, depending on volume targets.

Tooling tolerances are maintained to ensure consistent fill and ejection cycles. Our vertical clamp injection molding machines operate between 25 and 50 tons of force, with injection temperatures controlled between 320 °F and 450 °F (160 °C and 232 °C) depending on resin type.

Parting lines, gate profiles, and vent channels are configured to control flash thickness and minimize gate witness on the finished product.

Custom overmolded cable assemblies are molded using thermoplastic materials such as PVC, PE, PP, TPU, TPE and silicone.

Shore A durometer values range from 40A to 95A based on application strain relief requirements. TPU and silicone compounds are selected for medical or instrumentation assemblies needing wide operational temperature tolerance, from -94 °F to 392 °F (-70 °C to 200 °C).

All materials are RoHS-compliant and available with UL94 V-0 flame ratings. Jacket compatibility is validated through pull testing and cross-section bonding analysis.

WellPCB molds over MIL-DTL-5015, D-sub, M12, SMA and custom shell connectors with 360° encapsulation.

Backshells and cable interfaces are overmolded with anchoring ribs and internal retention barbs where applicable.

Typical strain reliefs are designed for 10× cable OD bend radius and 35 to 55 lb axial load retention on 18 to 24 AWG conductors. Overmold exit geometry can include straight, 90°, 45° or custom molded cable boot transitions depending on the enclosure layout.

EMI shielding is integrated by anchoring foil and braided shields directly into the mold using compression rings and tie-down anchor tabs.

Overbraided or foil-shielded molded cable assemblies maintain DC continuity from the connector shell through the cable braid, verified using Kelvin 4-wire measurements.

EMI testing is conducted using impedance analysis up to 100 MHz, with target shield resistance below 2 ohms across the assembly length.

We embed molded part numbers, date codes and logo plates into the cavity tooling. Pad-printed, laser etched, and heat-transfer sleeve options are also available for serialization and tracking.

Tooling inserts allow fast swaps for different wire counts, cable jacket sizes and connector configurations, supporting build variants without full mold redesign.

WellPCB supports rapid tooling with 3D-printed SLA cavities for under-100-piece pilot runs. Injection molding pressure is tuned down to 80 psi for low pressure molding cycles that prevent displacement of delicate inserts.

These tools support cavity cycles up to 100 before thermal degradation or shrink deviation is observed. Injection molded assemblies are delivered with full continuity, insulation, and dimensional inspection reports, even for one-off builds.

Custom overmolded cable assemblies for medical use are built to IATF16949 and ISO9001 with biocompatible TPU or silicone.

Overmold hardness typically ranges from Shore A 70 to 80, with sterilization resistant formulations tested to 100+ autoclave cycles at 275 °F (135 °C).

Automotive assemblies use flame rated PVC or Santoprene compounds, validated to FMVSS 302 for flammability and subjected to thermal shock cycling from -40 °F to 221 °F (-40 °C to 105 °C).

For industrial applications, we design for IP68 ingress, 50 lb strain retention, and shield continuity to below 1.5 ohms.

Every molded cable assembly is electrically verified with Cirris Signature Touch or Cablescan pin-mapping systems and tested for continuity, insulation resistance and strain force in accordance with UL and CSA requirements.

Visual inspections include ejector pin witness marks, cavity fill completeness, and flashing thickness. Pull tests are conducted to failure or specified minimum (30 to 50 lb for jacketed 20 AWG PVC).

Test reports include serial traceability, compound lot number, and cavity ID to match IPC/WHMA-A-620 Class III production requirements.