Overmolded Cable Assembly Manufacturers & Suppliers in India | Elcab Conductors

Overmolded Cable Assembly Manufacturers in India | Elcab Conductors

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Elcab Conductors is topmost overmolded cable assembly manufacturers, suppliers in India. With granting our Cable Assemblies, you have the game-changer. This is the reason why we inject a hardy thermoplastic material smoothly around the fragile cable-to- connector interface and this removes the probability of failure due to bending, moisture and vibration. Different industrial machinery, sensitive medical devices, or the high-pressure automotive industry, either way you go, our high-quality will ensure longevity in performance and highly limited downtime.

What is Overmolded Cable Assembly?

An Overmolded Cable Assembly is a conventional cable assembly which has been permanently enwrapped in a specially designed protective coating of plastic or rubber, usually by an injection molding procedure. This procedure produces one continuous and smooth and extremely resilient coating on the connector and around the highly sensitive cable-to-connector intersection.

Types of Overmolded Cable Assembly:

Being as leading overmolded cable assembly manufacturers in India, according to different methods we provided different types which are given below.

By construction method:

Two-shot: Two stage process in which initially the original material is molded and the part is transferred to a second cavity where a second material is injected.
Multi-shot: is a process of injecting several materials into a single mold.
Insert: A pre-shaped insert is fitted in the mold before the second material is introduced into the mold.

By protection and features:

Strain relief: Adhesive wrap that strengthens the cable around the connector to avoid mechanical force and bending.
Water-resistant: Overmolded cable assembly suppliers in India are a barrier against water ingress to allow greater durability in wet conditions.
EMI shielding: These is to guard against electro-magnetic interference.
Custom: Assemblies that are customized with specific design features with different featurers.

By connector type:

Circular: Assemblies, which are circular such as the M8, M12, and M16 series used in industrial and automation systems.
Coaxial: Assemblies consisting of coaxial plugs in OverMolded Wire Assembly Suppliers in India.
D-sub: Connector assemblies: D-subminiature connectors.
Modular: Assemblies that use modular plugs and jacks such as Ethernet.
Rack and Panel: Assemblies that have rectangular rack and panel connectors.

By application:

Medical: Cable assemblies in medical equipment with high reliability that have special sealing or protection requirements.
Industrial: Assemblies designed to be highly rugged industrial and typically having features such as water resistance or EMI shielding.

For rugged, connectorized applications, check out our M12 Connector Cable Assembly Manufacturers in India section that complements our overmolded assembly range.

Technical Specifications of Overmolded Cable Assembly:

We've added below a specialized table of Overmolded Cable Assembly in India that provides further technical specification information.

Specification Category	Key Feature	Common/Typical Specification	Purpose/Benefit
Connector Type	Circular	M8, M12, M23	Industry standard for sensors, actuators.
Protection	Ingress Protection (IP Rating)	IP67, IP68, or IP69K	Water-resistant & Dust-proof. Protects against moisture, dust.
Mechanical	Overmold Material	TPU (Thermoplastic Polyurethane) or PUR (Polyurethane)	Provides excellent Strain Relief, and high flexibility.
	Cable Jacket Material	PVC (economical), PUR (rugged, oil-resistant)	Determines resistance to abrasion, flexing, and chemicals in the environment.
	Strain Relief	Integrated/Seamless due to overmolding	Prevents wire breakage and damage at the critical cable-to-connector junction from pulling and bending.
Electrical	Rated Voltage	30V to 250V Varies significantly by pole count/coding	The maximum safe operating voltage for the assembly.
Electrical	Rated Current	1.5A to 4.0A Varies significantly by pole count/coding	The maximum safe operating current for the assembly.
Environmental	Temperature Range	−30°C to +85°C	Ensures reliable operation in industrial environments.
Environmental	Shielding	Foil and/or Braid ($360^\circ$ Shielding)	Provides EMI Shielding to guard against electromagnetic interference.

Benefits of Overmolded Cable Assembly.

As overmolded cable assembly suppliers in India, we provided different benefits which are given below.

Superior Strain Relief: Overmolding Circular Connectors in Cable Assemblies is a good measure in ensuring that the internal wires do not break or get damaged when the cable is being pulled or bent or flexed repeatedly thus dramatically increasing the lifespan of the product in terms of functionality.
Engineered to be more environmentally friendly: The seamless seal has a high Ingress Protection (IP rating) to resist all kinds of harmful substances such as moisture, dust, oil, and other industrial fluids in overmolded cable assembly manufacturers in India.
Better Aesthetics and Branding: The enigmatic look of Overmolding also gives it a smooth, business-like and completely unified look that is much better looking than multi-piece products.
Shock and Vibration Resistance: This is vital in use in vehicles, heavy machinery and robotics where continuous movement would otherwise cause regular, non-enclosed connections to loosen and break.

Key Characteristics of Overmolded Cable Assembly:

We as leading overmolded cable assembly manufacturers in India, different key characteristics which are given below.

Selection of Molded Material: We use such specific materials as PVC, TPE, and Polyurethane that are selected due to their strength, elasticity, and ability to withstand chemicals or high and low temperatures in OverMolded Wire Assembly Manufacturers in India.
Integrated Strain Relief: One of the fundamental features is an integrated strain relief in which the molded body itself acts as a bend restraint at the connection point itself, a crucial consideration in the long term cable reliability.
Custom Tooling and Geometry: Our operation involves the precise molds that are capable of producing unique forms such as right angles or a low profile to accommodate the tight and limited areas.
Sealed Ingress Protection: The smooth encasing provides a barrier that is very resistant to the infiltration of water, dust, as well as oils of different kinds.

Applications of Overmolded Cable Assembly

Serve as leading overmolded cable assembly suppliers in India, it is applicable in different sites which are given below.

Medical Devices: These are necessary when the medical equipment is complex such as the imaging diagnostic equipment, patient monitoring equipment, where reliability of the product is the ultimate factor, sterilization resistance and patient safety cannot be compromised.
Industrial Machinery and Robotics: Industrial use of CNC machines, robot arms, and other types is used widely in factory automation, manufacturing oils, manufacturing high-flexibility requirements, and high-levels of mechanical stress and movement.
Telecommunications Infrastructure: This is vital in interconnecting elements in servers, routers, and network equipment rooms to facilitate efficient and reliable data transmission and power delivery in the multidate data systems in overmolded cable assembly manufacturers in India.
Military and Defense: Used in hard working applications like soldier communication equipment, tactical vehicles and radar equipment, which demand great ruggedness, life and reliability, and tested capability in extreme environmental conditions.

Why Select Us as an Overmolded Cable Assembly?

Proven Manufacturing Excellence: Years of experience We possess years of experience in manufacturing to the highest quality control and to industry regulatory standards.
Complete Customization of Designs: We provide absolutely full customization, including selecting the material to the last detail and custom code of color, as well as combining the small PCBs into the overmold.
Fast-Track Prototyping: We employ the latest 3D modeling and quick tooling techniques to make available and test your prototype assemblies in a very short time, cutting drastically on your product development cycle.

Elcab Conductors is outstanding overmolded cable assembly manufacturers, suppliers in India. Cable failure will not reduce your progress! Halt making pathetic weak relationships. Swap your Stock Overmolded Cable Assemblies and bet on the lifetime performance and reliability of the entire product range. It is not a mere cable, it is a performance guarantee, a safety shield and a continuation of your brands quality. Get in touch with us and shape your ideal, high-performance relationship!