Molded connector and cable exit
A molded body stabilizes the termination and shapes a straight, side or angled cable exit. The design controls wall thickness, lock access, mating clearance and bend transition.
Product type
Overmolded Cable Assembly
OverviewOvermolded cable assemblies encapsulate the connector-to-cable transition with a selected thermoplastic or elastomer to provide defined strain relief, sealing, touch protection, geometry and appearance. The result depends on the complete interface, cable jacket, molding material, insert preparation and process window.
Popular Product Photos
01 / 16
Multi-Pin Rectangular Connector 1-to-2 Jacketed Harness
Bulkhead Cable Gland Multi-Core Adapter Harness
White Socket to Terminal Jacketed Harness
Circular Connector to Rectangular Plug Branch Harness
Circular 3-Port T-Branch Harness
5150 Whips 2-Branch Y-Branch Adapter Harness
QM 0H Push-Pull Circular Connector to USB & D-sub Harness
C-NAV5000 COM 2-4 USB Branch Harness
DIN43650 Circular Adapter Solenoid Valve Harness
DIN Solenoid Valve Right-Angle Plug Harness
Quick-Connex DIN Connector to Circular Plug Harness
Right-Angle Circular Connector Y-Branch Jacketed Harness
4-Branch Compact Circular Connector Harness
4-Branch 12V Power Distribution HarnessBA5590
M12 3-Pin Connector to Ring-Terminal Harness
Circular Connector to Spade-Terminal Harness
Product Introduction
Connector protection, strain relief and molded geometry developed as one system
Overmolded cable assemblies cover far more than one connector style. They include straight or angled cable exits, soft strain-relief boots, hard shells, sealed junctions, molded branches, PCB or sensor encapsulation and two-shot constructions. The electrical termination is completed first, then the insert, cable jacket and molding resin are combined through a controlled tool and process. Material labels alone cannot predict adhesion, sealing or flex life, so geometry, preparation and validation must follow the actual assembly.
Overmolded Assembly Configurations
Soft strain-relief boot
Flexible ribs or a tapered boot distribute bending away from the termination. Hardness, rib spacing, jacket grip and free cable length are tuned for the intended movement.
Hard-shell overmolded connector
A rigid molded body can create handling surfaces, polarization, mounting features or touch protection while preserving the original mating interface and tolerances.
Molded splice and branch junction
Splices, electronic components or multi-cable breakouts can be encapsulated when cavity filling, heat input, wire position and serviceability are reviewed.
Low-pressure electronic encapsulation
Sensitive boards, sensors or modules may use a low-pressure molding route to reduce component loading. Resin, board cleanliness, connector masking and heat exposure remain project specific.
Pre-mold plus final overmold
A hard or stabilizing pre-mold can secure terminals, shields and components before the final cosmetic or flexible layer is applied. The two materials need a compatible interface.
Molding and Cable Material Recommendations
Conductors, terminals and internal terminations
Current, voltage drop, signal function and crimp or solder geometry are confirmed before molding because the finished termination may no longer be accessible for correction.
Insert, shell and mechanical locking
Metal and plastic inserts need retention features, clean surfaces and controlled clearances. Knurls, undercuts, holes or pre-mold geometry can provide mechanical locking when chemical adhesion is limited.
TPE, TPU, PVC, PA and low-pressure resins
Material selection considers hardness, melt temperature, shrinkage, abrasion, oils, chemicals, UV, flammability and compatibility with the insert and cable jacket. No resin is universal.
Cable jacket and thermal compatibility
The cable jacket must tolerate molding heat and pressure without softening, distortion or migration. Surface energy and additives can also change adhesion to the overmold.
Overmolding Engineering Solutions
Design from the interface and duty cycle
Mating clearance, user handling, cable pull direction, bending, sealing, chemicals and assembly space define the molded envelope before a tool is selected.
Review existing tooling without forcing a fit
An existing tool may reduce development work only when insert position, cable diameter, interface clearance, gate, parting line and performance requirements genuinely match.
Control insert position and cavity filling
Fixtures support connectors, cables, shields and components against injection movement. Gate and vent locations are arranged to fill thin sections without trapping air or displacing wires.
Validate the molded assembly, not just its appearance
Dimensions, continuity, mating, cable pull, bending, section cuts, sealing or environmental tests are selected according to the actual failure risks and agreed acceptance limits.
Industries and Applications
Industrial sensors and actuators
Overmolding can protect compact interfaces and cable exits on sensors, valves, switches and actuators exposed to handling, vibration or contamination.
Automation and production equipment
Molded connectors provide repeatable handling and strain relief for equipment modules, fixtures and replaceable station cables.
Machine tools and service cables
Defined boots and rigid bodies protect connectors around oil, chips, vibration and frequent technician handling when materials are matched to the exposure.
Robotics and moving equipment
A tuned strain-relief transition can manage repeated cable movement, but flex life still depends on the cable, routing, bend radius and attachment system.
Appliances and commercial equipment
Molded junctions and plugs can combine touch protection, recognizable geometry, cleanability and repeatable assembly around motors, heaters and controls.
Instrumentation and test systems
Custom exits, shield terminations and compact molded bodies support probes, instruments and fixtures when signal requirements and grounding are defined.
Overmolded Cable Making Method
Requirement and interface review
Confirm electrical function, interfaces, cable, molded geometry, environment, loads, colour, quantity, validation and any tooling constraints.
Drawing and material definition
Define insert datums, cable exit, parting line, gate-sensitive faces, wall thickness, strain-relief profile, resin and inspection dimensions.
Electrical termination and pre-mold preparation
Complete crimping, soldering, splicing, shield termination and electrical checks, then stabilize and clean the insert for molding.
Tool setup and first-off molding
Set insert fixtures, temperature, pressure, speed, cooling and venting, then inspect short shots, flash, sink, cable movement and deformation on first pieces.
Dimensional, electrical and mechanical validation
Check molded dimensions, mating, continuity, polarity and appearance plus agreed pull, bend, section, ingress or environmental items.
Process release and repeat production
Release the approved drawing, BOM, tool setup, sample, work instruction and inspection plan as one controlled production reference.
Molding and Reliability Review
Cable pull, bending and strain transfer
Pull load and repeated bending can concentrate at the conductor termination if the boot is too stiff, too short or poorly bonded to the jacket.
Chemical, moisture and jacket interaction
Oils, cleaners, water and plasticizer migration can change resin, jacket and interface behavior. Compatibility needs representative materials and conditioning.
Internal electrical integrity after molding
Heat, pressure and insert movement can disturb terminals, solder joints, shields or components, so post-mold electrical checks remain mandatory.
Sealing and performance claim boundaries
Overmolding can support sealing, but any ingress, temperature, flame or endurance claim requires a defined specimen, method and acceptance limit.
What Controlled Overmolding Improves
More stable connector-to-cable transition
Controlled molded geometry distributes handling and bending loads while protecting the internal termination from direct contact.
Repeatable form and assembly orientation
Tool-controlled exits, keys, grips and mounting features reduce assembly ambiguity across repeated builds.
Integrated protection around compact electronics
Suitable processes can combine insulation, component support, touch protection and environmental covering within a compact envelope.
A controlled molded cable product
Electrical assembly, material set, tool, process settings, dimensions and inspection points are released together instead of treating molding as decoration.
Frequently Asked Questions
What is the difference between overmolding and using a separate boot?
Overmolding forms material directly around the insert and cable in a tool, creating a controlled integrated geometry. A separate boot is assembled afterward and may not provide the same retention, sealing or dimensional control.
Which molding material should be used?
The choice depends on hardness, flexing, temperature, chemicals, abrasion, flame requirements, colour, cable-jacket compatibility and processing temperature. A material name alone is not enough.
Can an existing mold be reused?
Possibly, after insert position, cable diameter, interface clearance, exit direction, parting line, gate and required performance are compared. Similar appearance does not guarantee fit.
Does overmolding automatically make a cable waterproof?
No. Sealing depends on the complete interface, material compatibility, cable jacket, insert geometry, molding quality, mating condition and the agreed test configuration.
What information is required for quotation?
Provide connector and insert data, pin map, cable construction and diameter, molded dimensions, exit direction, material or hardness target, environment, quantity and required validation. A physical sample can support review.
Which inspections are performed before shipment?
Finished assemblies receive continuity and appearance inspection plus dimensional, mating, lock, flash, deformation and other agreed checks. Pull, bend, ingress or environmental tests follow the approved project plan.
PART NUMBER / INTERFACE / MATERIAL
Models, Part Numbers & Sourcing
Find a cable model or material part number, then send it for a custom replacement or original-part sourcing review.
No matching references. Try a brand, full part number or a listed alias.
Cable & Harness Models
Finished cable and harness references for this interface or application.
- Molex
2451350810
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
- Tensility
10-03449
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
- Tensility
10-03446
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
- Tensility
10-03443
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
- Tensility
10-03440
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
- Tensility
10-03437
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
- Tensility
10-03434
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
- Tensility
10-03431
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
- Tensility
10-03428
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
- Tensility
10-03425
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
- Tensility
10-03422
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
- Tensility
10-03419
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
- Tensility
10-03416
Overmolded rectangular cable assembly
Custom compatible replacements · Original-parts sourcing
Connector & Material Part Numbers
Connector, wire and process-material references for project selection.
- Teknor Apex
Medalist MD-84348
TPE grade for medical cable jackets and molded connectors
Custom compatible replacements · Original-parts sourcing
- Tensility
30-01337
Cable wire material
Custom compatible replacements · Original-parts sourcing
- Teknor Apex
Medalist MD-84368
TPE grade for medical cable jackets and molded connectors
Custom compatible replacements · Original-parts sourcing
- Tensility
30-01313
Cable wire material
Custom compatible replacements · Original-parts sourcing
- Teknor Apex
Medalist MD-84383
TPE grade for medical cable jackets and molded connectors
Custom compatible replacements · Original-parts sourcing
- Tensility
30-01289
Cable wire material
Custom compatible replacements · Original-parts sourcing
- Teknor Apex
Medalist MD-84388
TPE grade for medical cable jackets and molded connectors
Custom compatible replacements · Original-parts sourcing
- Tensility
30-00686
Cable wire material
Custom compatible replacements · Original-parts sourcing
- Tensility
30-00383
Cable wire material
Custom compatible replacements · Original-parts sourcing
- Tensility
30-00368
Cable wire material
Custom compatible replacements · Original-parts sourcing
Configuration & Project Review
01 Insert and mating envelope
Confirm connector part numbers, latch travel, keying and space that the mold must leave clear.
02 Jacket-to-resin interface
Select the mold resin with the actual cable jacket and insert materials; verify adhesion on assembled samples.
03 Cable exit and support
Define exit angle, supported length, bend clearance and the cable pull direction at installation.
04 Mold and thermal exposure
Review gate location, insert positioning, molding pressure and thermal exposure against the connector limits.
05 Seal boundary
Specify the required sealed interfaces and test the completed assembly in its actual mating state.
06 Controlled first article
Approve molded dimensions, flash limits, pin mapping and electrical tests before releasing the tooling revision.
Send the part number, drawing or sample to confirm the replacement configuration and sourcing plan.