All You Would Want To Know About Overmoulded Cable Harnesses - Miracle Electronics

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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 relief area.
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 India whose 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 specific applications.
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Which materials are used for overmoulded cable
harnesses? 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 used on. What are
the advantages of overmoulded cable
harnesses? 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 application requirements. Where is
overmoulded cable harnesses used? 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 sterilization
compatibility. 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 harnesses that 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 of
application. For more information visit Miracle
Electronics