QL- Custom Technology Limited is a professional company that specializes in Custom made Over molding cable assembly and wire harnesses. Overmolded cables are full assemblies that combine the wire and connector into one single, seamless piece. To do this, the cable assembly is placed inside a mold. Next, molten plastic material is injected into the mold cavity. QL-Custom operates in a modern facility that houses warehousing, engineering, production, and important support activities at hand to satisfy all our customers. Superior product line The range of products in the plastic molding category includes GPS position track devices, vacuum cleaner parts, outdoor/indoor parts, speaker frames, molded connectors, and sockets, as well as other plastic products. Our cable products have grown in popularity to make us a world-class supplier of important items including custom molded cable, automotive wire harness, solar cables, and other wire solutions customized for individual customers. QL-Custom will work with clients throughout the entire process to produce the designs you desire to your specifications. The quality department will analyze all products using advanced testing apparatus before we quickly deliver the parts to your preferred destination. We certainly have the ability and capacity to meet virtually any needs you might have with regards to plastic molding and cable harness, relying on our time-tested quality workforce to assure products that will never let you down.

Custom Molded Cables

From extreme environmental stresses to the strains of abrasion and high-repetition movement, molded cable assemblies must be built to last. Without rigorous attention to the demands found in the field, a single cable assembly can lead to downtime, lost productivity, and decreased ROI. That’s why Cypress Industries ensures that each custom cable assembly is designed, manufactured, and tested according to the strictest specifications.

We review all of the demands imposed on each cable assembly and bring a wealth of options to the table. After choosing the right materials (we work with PVC, rubber, Santoprene, ABS, Polycarbonate (PC), Macromelt, and many others) we identify the best production processes. Each stage of pre molding, potting and overmolding is reviewed. We provide the right mix of waterproofing and abrasion resistance, meeting IP67 and IP68 standards if necessary. Soldering and crimp joints are examined, and remolding, overmolding, or both can be incorporated to secure the connections and provide strain relief, durability, and long, useful life. We can design custom potting fixtures machined in specific shapes, adding coatings to the potting fixtures to ensure a good release and a clean finish. We also provide potting of junction boxes to provide weatherproof seals.

Benefits of overmolding
To do this, the cable assembly is placed inside a mold. The first material (the substrate) is covered by the other materials in this process. Our skilled engineering and sales reception capabilities on industrial cable assemblies can respond quickly to customer inquiries, like Military connectors, Aviation Connectors these industrial cables. We assist in developing different cabling quality requirements in accordance with IPC620 industry standards. Fully work with your engineers, we can develop a product from an idea to a job as well as to meet the mass production of the customer.

Overmolded cable assembly internal components fortify protective qualities and help cable assemblies survive in even the most rugged environments. By overmolding your cable assemblies, you will:
• Increase the flexibility at the cable exit, where most of the movement between a cable and connector takes place
• Provide resistance to abrasion and shock or impact
• Make cable assemblies tamper-proof by encapsulating components beneath a sealed resin
• Provide 360-degree strain relief and increased pull strength
• Create a water-resistant or water-tight seal that qualifies cable assemblies for IP certification
• Improve the overall quality, appearance, and feel of cable assemblies, replacing the need for expensive metal backshells
• Simplify installation by creating a one-piece assembly with keys that act as visual indicators to assist in the mating of each pair
• Reduce human error

Cable Assembly Overmoldering Process

The over-molding of a cable assembly is accomplished by forcing material into a mold cavity under a great deal of pressure. For cable assemblies, the most popular materials used for an overmold are thermoplastic or thermoset materials. The injection molding machine, also known as a press, consists of a storage area for the mold resin. Sometimes it can be called a hopper. Delivery for the material is usually an injection ram or a screw-type plunger enclosed inside a metal tube also known as a barrel. Heating elements are installed into the barrel of the machine causing the mold resin to be heated to a molten state.

The process begins with the resin specified for the mold being fed into the heated barrel of the molding machine at the hopper end. It is then mixed with any desired colorants and transits the length of the barrel to the actual mold where the resin and colorant mixture is forced into the mold cavities. Once inside the mold cavity, the material will cool taking on any features designed into the mold itself including logos, trade names, or part numbers.

Molded strain relief

Strain relief is a standard fixture for electrical cables that functions as a feature for relieving the stress from the cable connections themselves to prevent them from breaking. It is located in the base of the connector where the connector meets the cable and usually comes pre-molded as part of the connector itself. It is the part of the connector that looks like a sleeve over the cable and is often segmented to allow some limited bending without problems.

On other cables, especially those that are manufactured separate from their connectors, strain relief often comes in the form of a separate device that is installed over the connector and the cable joint. In the case of network cables, the strain relief is called the “boot,” which is fitted over the connector after attaching the cable and the RJ-45 connector. In other connectors, the strain relief can be in the form of metallic connectors and grips, some of them made of metal that is crimped over the cable to provide tensile strength.

We understand the challenges and trends cutting across the electrical design processes across the world and our engineers are always ready to walk with you in this process. Our valuable integration resource saves time and costs for global customers thanks to an effective engineering team that is skilled and meticulous, always dedicated to delivering products that meet the highest standards as stipulated by industry standards. You are assured of a quick production process that is executed to precision.