A Guide to Over-molded Wiring Harnesses

The over-molded wire harness design provides molded external protection for electrical cable and harness backshells. The use of fluoropolymer elastomer and fluorosiloxane improves the strength, durability, fluid resistance, and vibration protection of the wire harness product.

What is Overmolded Wiring Harness

The over-molded design is a subset of the series of cables in the enclosed harness. The difference is that the backshells are encapsulated in protective material. This protective material is applied at the manufacturing stage by using a molding press and curing oven. Although it does limit the repairability of the wiring harness, it provides excellent moisture sealing and vibration protection for harsh environments and applications.

What are the benefits of overmolding?

Collectively, all the advantages of overmolding boil down to two things: greater lifespan and reliability. Overmolding shields internal components fortify protective qualities and help cable assemblies survive in even the most rugged environments. By overmolding your cable assemblies, you will:

1. Create a water-resistant or water-tight seal that qualifies cable assemblies for IP certification

2. Provide resistance to abrasion and shock or impact

3. Simplify installation by creating a one-piece assembly with keys that act as visual indicators to assist in the mating of each pair

Over-molded Wiring Harnesses

4. Make cable assemblies tamper-proof by encapsulating components beneath a sealed resin

5. Improve the overall quality, appearance, and feel of cable assemblies, replacing the need for expensive metal backshells

6. Provide 360-degree strain relief and increased pull strength

7. Increase the flexibility at the cable exit, where most of the movement between a cable and connector takes place

Common Applications

The most common applications that use overmolding include solar energy, military equipment, consumer electronics, medical equipment, and industrial/OEM applications. Overmolding is ideal for cable assemblies that will face extreme weather, high-pressure washing, continuous sanitation, frequent strain and bending, and exposure to dust or debris.

We are an over-molded wiring harnesses supplier, please feel free to contact us if you need them.