Over molded cable assemblies undergo a process named Over-molding. It is a process in which a product is produced by injecting the material into a mold cavity under high pressure. The principle on which over-molded cable assemblies are manufactured is quite familiar to injection molding. Theoretically, Injection molding is quite simple, melt plastic, inject it into a mold, let it cool and, then, out pops a plastic product. But in reality, it is a very complex process. The machine that is used comprises of three parts the injection unit, the mold and the clamp. The injection unit injects the molten plastic into the mold. In the mold, air is inserted through smaller patches so that it helps plastic to cool down quickly. After the plastic is cooled the mold is opened and the clamp help to remove the plastic product from the mold and the process repeats. (Figure 1)
In an over molded cable assemblies, the connector and the cable becomes a single part. It makes over molded cable assemblies more powerful, waterproof and flexible. It also enhances the protection of the cable assembly because there is hardly anything that can penetrate the over-molded cable assemblies. The cable assemblies have to meet IP67 and IP68 standards. Different pallets of plastic could be added for coloring purpose e.g. PVC, rubber, Santoprene etc.
Sometimes there is a need for pre-molding, It means the there should be some point of the cable assembly where one can assemble screws or place whole. Now, pre-molding is done before over-molding and that is also used as a foundation for the over molding in some over molding cable assemblies.
After post production of over molded cable assemblies, these cables undergo a detailed analysis of their electrical connectivity and conductivity. It is keenly checked that the connectors and the cable assembly are successfully intact. A proper analysis is made to check that either the cable meets the electrical standards and customer’s requirements.