Overmolded Cable Assemblies

Overmolded Cable Assemblies Including Overbraided, Shielded and Caustic Chemical-Resistant Designs for Harsh Environmental Interconnect Wire Harness and Cable Assembly Applications

Overmolded Cable Assemblies are the most rugged class of interconnect wire-harnessing available. Overmolding is the preferred solution for environmental protection of military, aerospace, and harsh-environment industrial interconnect cable assemblies. In fact, the typical interconnect cable assembly made for high performance applications — from fighter jets to dismounted soldier systems — has little in common with their more pedestrian cousins in the consumer product arena including better overmolded cable and connector sealing materials, as well as better mechanical / bend protection, shielding from electromagnetic interference, superior wire termination strain-relief, higher IP levels of environmental sealing and superior all-around durability performance.

Glenair: Where Connector Manufacturing and Overmolded Cable Expertise Meets Cable Harness Assembly

If there is one thing we understand well at Glenair, it's how to build environmentally-sealed overmolded interconnect cable assemblies for high-reliability systems. In fact, when it comes to protecting both electrical and optical media from mechanical stress, corrosion damage, lightning strike, physical abuse, nuclear, biological or chemical contamination and more, there is no more experienced overmolded cable assembly operation in the business than Glenair. In large part this is due to our extensive interconnect component design and manufacturing capabilities combined with our many years of experience in military grade and harsh environmental commercial cable harness fabrication.

Overmolded Cable Assemblies

Terminated, tested, overmolded, and ready for use, Glenair environmental overmolded cable assemblies may be supplied with MIL-M-24041 materials as well as other molding materials including Viton^®, Duralectric™, polyurethane, EPDM, Santoprene™, polyamide and more. Fast turnaround and quality fabrication in overmolded cable assemblies depends on capital investment in tooling and injection molding equipment. Glenair operates the largest and most well-equipped overmolding shop in the high-reliability cable industry.

Advantages of Overmolding

Waterproof sealing
Robust mechanical protection
Permanent protection of terminations
Resistance to chemicals and fuels
No induced cold flow stress
Electrical isolation and insulation
Reduced damage from wear
Flexible routing/cable entry
Repeatable assembly performance

Overmolded Cable Assembly Application Examples

	Commander Ed White's, "Golden Umbilical" With space-grade radiation shielding Overmolded connector protection On display at the Smithsonian Air and Space Museum
	Overmolded Power and Signal Cable Assembly Color-Coded with special 90° Overmolded junctures
	Overmolded TurboFlex® Power and Signal Tank Pylon Assembly
	Tight-Tolerance Multibranch Fighter Jet Assembly Caustic fuel-resistant Viton overmolded solution
	Repairable Accordion Boot-Equipped Overmolded Assembly
	Hybrid Overmolded and Tape-Wrapped Assembly
	Overmolded Point-to-Point Assembly With Coil Cord Cabling
	Commercial Overmolded Aircraft Assembly With Duralectric™ Overmolding and Mighty Mouse Connectors
	Hybrid Abrasion-Resistant Overbraided Cable Assembly With Overmolded Cable Junctions
	Head-Up Display (HUD) Cable With Custom Series 804 Mighty Mouse and Low-Profile Cable Routing, overmolded connector protection