Description

Robust & Reliable: Precision-Engineered Moulded Cables

In demanding industrial, commercial, and consumer applications, the integrity of your cable connections is paramount. Our Moulded Cables offer a superior, integrated solution, combining high-performance cables with permanently overmoulded connectors. Designed for unparalleled durability, environmental resistance, and long-term reliability, these cables eliminate common points of failure, ensuring seamless operation for your critical systems.

What are Moulded Cables?

Moulded cables are assemblies where the connector is permanently formed onto the cable through an injection moulding process. Unlike crimped, soldered, or field-attachable connectors, the overmould creates a seamless, robust, and sealed junction between the cable and its termination. This specialized manufacturing technique results in a highly durable, vibration-resistant, and environmentally protected connection, ideal for harsh conditions and high-cycle applications.

Key Features

• Integrated Design: Seamless fusion of cable and connector for maximum mechanical and environmental protection.
• Superior Strain Relief: The overmoulding process provides exceptional strain relief, preventing wire breakage and connection failure at the cable exit point, even with repeated bending or pulling.
• Environmental Sealing: Achieve high ingress protection (IP ratings like IP67, IP68) against dust, water, moisture, and various chemicals, making them ideal for outdoor or harsh environments.
• Vibration & Shock Resistance: The solid, integrated structure offers enhanced resilience against vibrations and mechanical shocks, crucial for industrial and mobile applications.
• Consistent Quality: Manufactured under controlled processes, ensuring uniform product quality, precise dimensions, and reliable performance across every unit.
• Customization Options: Extensive choices for cable types, connector configurations, overmould materials, colors, lengths, and pinouts to precisely match your application requirements.
• Enhanced Aesthetics: A clean, professional finish that contributes to the overall appearance and perceived quality of your product.
• Wide Material Compatibility: Available with various cable jackets (PVC, PU, TPE, LSZH) and overmould materials to meet specific flexibility, temperature, chemical resistance, and flame retardancy needs.

Benefits

• Maximized Durability & Longevity: Significantly extended lifespan compared to traditional cable assemblies, reducing replacement costs and maintenance.
• Reduced Downtime: High reliability minimizes connection failures, ensuring continuous operation of your equipment and systems.
• Optimal Performance in Harsh Conditions: Guaranteed functionality in environments exposed to moisture, dust, extreme temperatures, oils, and chemicals.
• Simplified Installation: Pre-terminated and tested, offering plug-and-play convenience and reducing on-site assembly time and labor costs.
• Cost-Effectiveness: While the initial cost might be slightly higher, the long-term benefits of reduced failures, maintenance, and improved operational efficiency lead to significant savings.
• Design Flexibility: Tailored solutions enable perfect integration into your product design without compromises.
• Safety & Compliance: Manufactured to meet relevant industry standards and certifications (e.g., RoHS, REACH, UL, CE) ensuring safety and regulatory compliance.

Typical Applications

Our moulded cables are essential components across a diverse range of industries, including:

• Industrial Automation: Sensor cables, actuator cables, robotic interconnections, fieldbus cables (e.g., M8, M12).
• Medical Devices: Patient monitoring equipment, diagnostic tools, surgical instruments requiring sterile and reliable connections.
• Automotive: Sensor connections, infotainment systems, diagnostic cables, and charging cables where resilience to vibration and fluids is critical.
• Consumer Electronics: High-durability USB cables, power adapters, audio/video cables, and specialized device connectors.
• Telecommunications: Outdoor network equipment, base station interconnections, and robust data links.
• Renewable Energy: Solar panel connections, wind turbine sensors, and battery management systems.
• Military & Aerospace: Ruggedized data and power connections for mission-critical equipment.
• Marine: Underwater sensors, navigation systems, and equipment exposed to saltwater.

Technical Specifications (Customizable)

• Cable Types: PVC, PUR/PU, TPE, LSZH (Low Smoke Zero Halogen), Silicone, Coaxial, Multi-conductor, Shielded & Unshielded.
• Connector Types: USB (Type A, B, C, Micro, Mini), RJ45, M5, M8, M12, M23, D-Sub, Circular DIN, Custom Proprietary Designs, Power Connectors (e.g., IEC, NEMA).
• Overmold Materials: PVC, TPE (Thermoplastic Elastomer), TPU (Thermoplastic Polyurethane), Nylon.
• Wire Gauge (AWG): From 30 AWG up to 10 AWG (depending on application).
• Voltage Rating: Up to 600V (depending on cable construction).
• Current Rating: From milliamps to tens of amps.
• Temperature Range: Typically -40°C to +105°C (material dependent).
• IP Rating: IP65, IP67, IP68 (or higher, depending on connector and overmold design).
• Compliance: RoHS, REACH, UL Recognized, CE, IEC, VDE.
• Length: Fully customizable from a few centimeters to hundreds of meters.

Customization & Design Support

We understand that every application is unique. Our team of experienced engineers works closely with you to design and manufacture moulded cables that precisely meet your specifications. Our customization options include:

• Cable Configuration: Choose jacket material, gauge, number of conductors, shielding, color, and flexibility.
• Connector Integration: Select from a vast array of standard connectors or design custom housings for specialized applications.
• Pinout & Wiring: Define specific wiring configurations, including hybrid cables (power + data + signal).
• Overmold Characteristics: Material hardness, color matching, company logos, text, or specific geometries for improved ergonomics or mounting.
• Length & Packaging: Precision cut lengths, custom labeling, and bulk or individual packaging options.
• Prototyping: Rapid prototyping services to validate designs before full-scale production.

Why Choose Us?

With years of expertise in cable assembly manufacturing, we are committed to delivering the highest quality moulded cables. Our dedication to precision engineering, rigorous testing, and customer-centric service ensures you receive products that exceed expectations. Partner with us for reliable, high-performance connectivity solutions that empower your innovations.

Ready to enhance the reliability and performance of your systems?

Contact us today to discuss your specific requirements or to request a quote for your custom moulded cable project. Our experts are ready to provide technical assistance and help you find the perfect solution.