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Cable Assembly Overmoldering Process

The overmolding of a cable assembly is accomplished by forcing a material into a mold cavity under a great deal of pressure. For cable assemblies, the most popular materials used for an overmold are thermoplastic or thermoset materials. The injection molding machine, also known as a press, consists of a storage area for the mold resin. Sometimes it can be called a hopper. Delivery for the material is usually an injection ram or a screw-type plunger enclosed inside a metal tube also known as a barrel. Heating elements are installed into the barrel of the machine causing the mold resin to be heated to a molten state.

The process begins with the resin specified for the mold is fed into the heated barrel of the molding machine at the hopper end. It is then mixed with any desired colorants and transits the length of the barrel to the actual mold where the resin and colorant mixture are forced in the mold cavities. Once inside the mold cavity, the material will cool taking on any features designed into the mold itself including logos, trade names, or part numbers.