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Overmoulded cable harnesses provide multiple advantages and are compatible to a variety of applications, provided the right materials and processes are used.
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Overmoulding has significantly changed the appearance and functionality of cable harnesses over the past many decades. Overmoulded cable harnesses are those that seamlessly combine wires and connectors together to form one single unit. The process of constructing such harnesses involves injecting a molten material into a mould cavity that fits into the desired shape when cooled. This mould cavity can be built as a simple design with no markings, or a complex design with inclusions of company name, logo, flanges, and strain reliefarea. Before beginning the production of Overmoulded cable harnesses, the entire harness is reviewed to ensure that it meets the expectations of the customers and requirements of the application. This review determines the best process for each stage of the manufacturing cycle including pre-moulding, potting, and Overmoulding. These processes include the perfect mix of waterproofing, electrical performance, and abrasion resistance. Another element that can be considered during the review is the standardization like IP67 and IP68. Miracle Electronics is one of those cable harness manufacturers in Indiawhose production processes are certified for quality to ISO 9001, AS9100C. Moreover, the quality of the products are also certified and approved by DGAQA and MSQAA for platform specificapplications.
Which materials are used for overmoulded cableharnesses? The materials to be used within an overmoulded cable harness should be considered and carefully chosen. The composition of the moulding material, the operating parameters of the moulding machine, and the appearance of the moulded cable harness should be considered as well. The most popular materials used for overmoulding are thermoplastic and thermoset materials. Some of the most popularly used ones are PVC, rubber, ABS, polycarbonate, polypropylene, polyethylene, santoprene, thermoplastic polyurethane, and macromelt. The materials of such cable harnesses can be color-coded to match the cable jacket or the equipment that they will be usedon. What are the advantages of overmoulded cableharnesses? Overmoulded cable harnesses can provide 360° strain relief, increased pull strength, and flexible support at the exit of the cable. They also provide protection from harsh environments, abrasion resistance, and increased electro-magnetic interference performance. Overmoulding has also allowed cable harnesses to have better functionality by letting them to become impermeable to fluids, and providing them the ability to withstand vibration, shock, and flexing without any damage. Furthermore, such overmoulded cable harnesses are cost-effective and ensured to meet the applicationrequirements. Where is overmoulded cable harnessesused? Overmoulded cable harnesses are used in a variety of applications like medical equipment, military equipment,etc. MEDICAL SEGMENT – Customized medical overmoulded cable harnesses are uniquely used in all their applications, utilizing component/PCB encapsulation, 360° EMI/RFI shielding, and multiple breakouts, providing watertight and ETO sterilizationcompatibility. MILITARY SEGMENT – Strain relief overmoulded cable harnesses for military connectors and other interconnects are used in military applications. Low pressure and overmoulding processes produce strong moulded custom cable harnessesthat can withstand various harsh environments. OTHER MARKET SEGMENTS –Overmoulded cable harnesses have excellent environmental resistance, flexible design, mechanical strength, and an aesthetic look, which makes them perfect for almost any kind ofapplication. For more information visit: MiracleElectronics
