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Essential components in everything from robotics to medical equipment, wire harnesses are bundled assemblies of wires and connectors used to transmit power and data. Designed to protect and organize wires while making installation and maintenance easier, wire harnesses must be manufactured with precision and the proper materials to fit the application. However, for optimal performance and durability, the highly effective process of overmolding is often used.
Overmolding involves placing the wire harness in a mold where injection-molding encapsulates it in an extra layer of plastic or rubber. Bonding the wires and connectors together during the curing process, overmolding creates a single unit which results in a number of desirable benefits and an overall better harness.
At CAI, we’ve made millions of custom wire harnesses, cable assemblies, and electrical components for satisfied clients in nearly every industry. Our global capabilities and integrated processes, including overmolding, ensure the highest quality and an optimal customer experience.
Here are some of the top benefits that our overmolding offers you and your next wire harness project:
The extra layer of durable material and the compact nature it produces result in an elevated level of protection compared to a regular wire harness. Creating a watertight seal that conforms to IP certification standards, overmolding helps guard the wires from moisture, chemicals, dust, abrasion, tampering, and continual wear and tear. This superior protection improves the wire harness’s longevity, especially in harsher environments.
While most of a harness’s movement takes place around the connectors, the enhanced support and flexibility of overmolding mitigates this stress, providing 360-degree strain relief and increased pull strength, far better than just backshells/adapters.
Overmolding offers additional electrical insulation from electromagnetic interference (EMI) and other threats to performance which enhances functionality. The overmolded layer also helps reduce the risk of short circuits which improves overall safety.
Whether in a vehicle, hospital, or factory, recurrent vibrations and shocks can cause havoc on wires and connectors. An overmolding layer helps to absorb the shuddering and shaking that can adversely affect the wires’ performance and reliability.
Wire harnesses can be an unsightly mess, even when ties and clips are used. By consolidating multiple wires into a single, more-manageable unit, overmolding helps reduce clutter and improve organization. It delivers a tighter, cleaner look and feel which is especially helpful when a harness will be exposed in its environment, and a professional, organized appearance is desired. Overmolding also provides a better canvas for branding opportunities through unique coloring and printed or embossed product or brand identification.
Rather than having to deal with multiple loose wires, overmolding permanently holds them and their connectors together. That, along with improved grip, makes for easier, quicker installation of the wire harness.
From superior protection to easier installation, the process of overmolding offers several benefits that make good wire harnesses great. From wire harnesses and cable assemblies to box builds and electro-mechanical assemblies, CAI has over 35 years of manufacturing experience in nearly every industry as well as global capacities that offer faster turnarounds and a better overall experience. Connect with us today for your unique electrical component needs!