Overmolded Cable Assemblies

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.

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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, Overmolded 'Golden Umbilical' Cable Assembly

Commander Ed White's, Overmolded "Golden Umbilical" Cable Assembly

  • With space-grade radiation shielding
  • Overmolded connector protection
  • On display at the Smithsonian Air and Space Museum
Overmolded Power and Signal Cable Assembly

Overmolded Power and Signal Cable Assembly

  • Color-Coded with special 90° Overmolded junctures
Overmolded TurboFlex™ Power and Signal Tank Pylon Cable Assembly

Overmolded TurboFlex™ Power and Signal Tank Pylon Cable Assembly

Tight-Tolerance Multibranch Fighter Jet Overmolded Cable Assembly

Tight-Tolerance Multibranch Fighter Jet Overmolded Cable Assembly

  • Caustic fuel-resistant Viton overmolded solution
Repairable Accordion Boot-Equipped Overmolded Cable Assembly

Repairable Accordion Boot-Equipped Overmolded Cable Assembly

Hybrid Overmolded and Tape-Wrapped Cable Assembly

Hybrid Overmolded and Tape-Wrapped Cable Assembly

Overmolded Point-to-Point Assembly

Overmolded Point-to-Point Assembly

  • With Coil Cord Cabling
Commercial Overmolded Aircraft Cable Assembly

Commercial Overmolded Aircraft Cable Assembly

  • With Duralectric™ Overmolding and Mighty Mouse Connectors
Hybrid Abrasion-Resistant Overbraided Cable Assembly

Hybrid Abrasion-Resistant Overbraided Cable Assembly

  • With Overmolded Cable Junctions
Head-Up Display (HUD) Cable with Overmolded Cable-Connector Junctions

Head-Up Display (HUD) Cable with Overmolded Cable-Connector Junctions

  • With Custom Series 804 Mighty Mouse and Low-Profile Cable Routing, overmolded connector protection