Cable Overmolding

Revolutionizing Cable Durability:
The Breakthrough in Overmolding Technology

What is cable overmolding?

Cable overmolding is a manufacturing process where a cable or wire harness is encased in a plastic overmold for enhanced protection and durability. This is achieved by injecting molten plastic into a mold that surrounds the cable assembly. Once solidified, the plastic forms a seamless cover over the cable, safeguarding it from environmental damages like moisture, heat, and abrasion. Commonly used in the production of electronic products, including power cords, USB cables, and audio/video cables, the overmold can be customized to the cable’s specific shape and size. It may also incorporate additional features such as strain relief and molded connectors. This process significantly increases the cable’s resistance to damage and prolongs its lifespan, making it an essential technique in modern electronic manufacturing.

Typical Overmolding comound: MIL-M-24041C / CONATHANE® EN-1556
Henkel Macromelt – Low Pressure Molding.

Advantages of Cable Overmolding

Cable overmolding enhances protection against environmental damage, extends cable lifespan, improves functionality, and offers customization for specific applications, all while maintaining cost-effectiveness.


Several materials are commonly used for cable overmolding, each suited to specific needs:

  • Thermoplastic Elastomers (TPEs): Offer flexibility and durability, ideal for various shapes and sizes.
  • Polyurethane (PU): Known for its toughness and abrasion resistance, suitable for high-wear scenarios.
  • Polyvinyl Chloride (PVC): Popular for its low cost, excellent electrical insulation, and resistance to moisture and chemicals.
  • Silicone: Flexible, durable, and resistant to high temperatures and UV radiation, ideal for harsh environments.
  • Nylon: Strong and durable, used where cables face high stress or tension.


Cable overmolding is vital in military applications for its durability in harsh conditions. Key uses include:

  • Communications Equipment: Protects cables in radios and antennas from extreme weather and damage.
  • Military Vehicles: Used in tanks, armored vehicles, and aircraft to shield cables from extreme temperatures, vibrations, and shocks.
  • Weapons Systems: Ensures cable integrity in missiles and guidance systems against shock and temperature changes.
  • Military Drones: Guards drone cables against extreme temperatures, moisture, and damage.

This technology is essential for the reliability and longevity of crucial military equipment and systems.

Ready to Start your Next Project?