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All Cable Sizes and Connector Types Accommodated

Cast Molded Parts Capabilities

In-house Mold Machining

Large Material Capacity

Overmolding

Overmolding is a manufacturing process that involves molding a second material over an existing part. This technique is commonly used to combine different materials, such as plastic and rubber, to create a single, cohesive product. Overmolding can reduce the need for secondary assembly processes by integrating components into a single part and by decreasing material waste. Overmolded products are more resistant to wear and tear, moisture, and temperature fluctuations.

Different Types of Overmolding

  • 2-Part Casted Overmolding provides a solid,seamless seal that chemically bonds to backshells and cables to protect against liquids, dust, heat and impact.

    Pros:
    Suitable for lower volumes or prototyping
    Multi-material production
     
    Cons: 
    Time consuming in manufacturing
    Not efficient for high volume production
     

    Examples of materials used are polypropylene, polyethylene, TPE’s and TPU’s, MIL-M-24041-spec polyurethanes along with low smoke/zero-Halogen options.

  • Injection Overmolding provides a solid, seamless seal that protects against liquids, dust, heat and impact. Injection Overmolding chemically bonds to cables, thermoplastics, backshells and other metals and offers superior aesthetics to 2-Part Casted Overmolding.

    Pros: 
    Applicable for complex or critical-use end products
    High volume efficiency
    Can provide a variety of surface finishes
     
    Cons: 
    Possible mold costs
     

    Examples of materials used are Technomelt®-PA-678, ESTANE®58244, ESTANE®58277 and Santoprene™.

  • The Full Rubber Overmolding  process is a vital part of CDM’s suite of value-added capabilities and has special advantages over conventional overmolding.

    Pros: 
    Seamless end product
    Enhanced flexibility and chemical resistance
    Accelerated manufacturing time
     
    Cons:
    Possible mold costs
    Higher materials cost
     

    Examples of materials used are EDPM, Fluorocarbon Elastomer (Viton®) and Neoprene.

In-House Support Operations

Overmolding

CDM’s 3,000 square-foot Turnersville, NJ, machine shop supports the overmolding program by providing molds and specialty components to make the entire process seamless to customers.

Overmolding vs Shrink Boots: What’s The Difference?

  • Overmolding

    • Provides a complete, seamless seal at the cable/connector junction
    • Provides an effective strain relief
    • Unlimited size, shape and color availability
    • Overmold material used is specific to the application
    • American made in-house at Turnersville, NJ under 100% quality control
    • Possible mold or prototype costs

  • Shrink Boots

    • Moisture and dust resistant, but not a true seal between the cable and connector
    • Shouldn't be used as a strain relief
    • Off-the-shelf sizes and shapes only, no color options
    • Very limited choice of materials
    • Mass produced and imported
    • Budget-friendly
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