At the core of design, Original Equipment Manufacturers (OEMs) encounter various challenges in their electrical designs. The minds behind innovative solutions and technological advances, navigate a terrain where the details of wiring can pose significant obstacles. We will take a closer look at those challenges and how Overmolding can bring a creative solution to seamlessly integrate, enhance durability, and boost overall operational efficiency.
Wiring Challenges OEMS face
OEMs engaged in outdoor applications tackle various wiring challenges in their operations. First, the exposure to harsh weather conditions poses a significant hurdle. Wiring within their products must withstand the extremes of weather, requiring robust solutions to maintain optimal performance. Additionally, protection against moisture, dust, and other environmental factors is crucial. The intricate nature of electronic components demands innovative approaches to shield against potential damage caused by these elements.
What is Overmolding?
Overmolding is a manufacturing process in which a secondary material, usually plastic, is molded onto an existing component like a cable or electrical connector. This technique results in a unified product with enhanced features, combining the strengths of both materials to improve durability, protection, and functionality. The process ensures robust protection for electrical connectors, creating a safer and more ergonomic mating process. Utilizing overmolded components in outdoor applications extends the life of contacts and connectors, safeguarding them from external elements like moisture and dust.
How Overmolding Addresses Common Wiring Issues
Adding an overmolded layer to a connector enhances the features of the original connector. Common wiring issues stem from the exposed conductors exiting the connector. Lack of strain relief, nicks or cuts in the conductors, terminals pulling out of the connector, and water ingress are just some issues that are resolved by overmolding. The overmold fully encapsulates the back end of the connector, including the conductors. As a result, there are no exposed conductors, and the issue of conductors getting nicked or cut is eliminated. This encapsulation also secures the conductors in place and prevents the terminals from pulling out of the connector. The overmold bonds to the cable and minimizes water ingress. The overmold provides strain relief for the cable which reduces stresses and damage due to bending. Working with a manufacturer who understands your application will provide you with the knowledge and guidance to get you the perfect solution.
Is Overmolding a good fit for your application?
Begin by taking a look at your customer's concerns. What concerns are you constantly revisiting with them? Are they having trouble with connectivity issues? Are the components experiencing corrosion long before they should? Is your equipment prone to continuous mating and unmating? Are you adding heat shrink or secondary components as a strain relief to your cable? If you answered yes to any of these questions you should consider overmolding for your connectors. Consider how your components are impacted by environmental factors to determine if overmolding is right for your application.
Additional benefits of Overmolding
In addition to the enhanced features of the connector, overmolding offers versatile customization options such as color options, diverse cable types, and custom labeling, providing added value. Color-coordinated harnesses improve organization and aesthetics. Custom labeling enhances functionality, aiding in troubleshooting, while custom branding options strengthen brand identity. These features collectively enhance the utility and appeal of the wire harness, making it an indispensable component for end-users in various industries.
Need Help defining if Overmolding is right for your application?
We're here to make the decision-making process easy and efficient. Not only do we provide expert guidance on connector compatibility and custom cable solutions, but we also handle the entire mold design process for you. To ensure a perfect fit, we offer prototypes before proceeding with production. Reach out to us today to discuss your specific requirements and we can discuss if overmolding is a good fit for you.
