Molded Cable Assemblies

Technical Cable Applications uses high quality MoldMan thermoplastic molding centers, to help with our molded cable assemblies for thousands of orders. We have been doing excellent, high quality cable molding work since 2002 but have only increased the speed of that work exponentially since then. Just in 2022 alone, we increased our molding cable capacity by 33% with an additional molding center purchase, along with increasing our entire facility’s real estate by 50%. We are always seeking to increase our molding, crimping and assembly capabilities, while continuing to have the same excellent quality control we’ve always maintained since starting in Auburn 20 years ago. 

Molded Cable Assemblies

We use custom tools called dies, sometimes based off a customer’s existing design if we’re just building cable assemblies based on it, and sometimes with an entirely new design based on the requirements of a new concept that we’ve already prototyped and prepared for production. These dies allow us to not only repeat the same shape and size of cable to exact specifications, but are also designed to be flexible and help produce different variations of the same design as needed, up to 12 per die. This is extremely helpful when we need to produce the same cable assembly but in a different orientation or angle. M12 connector dies can also have even more room for configuration which is very helpful considering the vast number of different industries that use them.

Custom Molded Cables

The materials we use for thermoplastic molding will be unaffected by heat all the way up to 475 degrees Fahrenheit, and we keep the materials environmentally sealed before using them in cable assemblies to make sure there will be no issue with the final product due to environmental factors in our facility. The molding machines we use can apply up to 2 tons of clamping force and use an extremely precise timed process for injection that allows us to control the temperature and pressure settings to the requirements for any given cable. All of this allows us to make excellent cables that can be molded to meet our customers’ needs and will last through the strenuous conditions they may have in their field.

Not only do we use top of the line materials and molding centers, we also employ the best staff available for our engineering and molding needs. If a cable requires new dies or very specific requirements for pressure, our team is the best in the business at making the adjustments needed so that the new cable solution will be highly reliable and durable. We give our engineers and production team members excellent benefits to ensure that they are always at their best capacity to make fantastic cable assemblies and moldings for our clients around the country.

Custom Overmolded Cable Assemblies

If a customer comes to us with a need for a custom molded cable assembly, we always follow these main steps to understand their needs and plan an order: 

  • Come to an agreement on the objective of the new custom cable’s performance and applications. If our customer doesn’t have a completed cable drawing/finished cable available for us to base the full production run on, we can offer advice and even help design new drawings and concepts that will accomplish the needs the customer has for a molded cable.
  • Confirm the manufacturing time required and steps involved for the custom molded cable assemblies. We will determine whether we have an existing cable die design ready for the project, or if we need to create a new die concept that will have multiple configurations. We also will confirm whether there is a need for the use of pre-molding epoxy for additional protection of shielding, flow through current or exposed conductors, and finally an estimate of the time required for manufacturing each assembly to complete the production.
  • Decide which cable material will be most optimal for the cable assembly need. One of the most common materials we use at the time of writing is the Macromelt OM 946, which is a type of polyamide. It’s rated as 92A on the hardness scale and can operate safely without any problems at temperatures as low as 40 degrees Celsius, or as high as 125 degrees Celsius. 

Our molded cable assemblies are utilized by clients all over the country to improve their products and ensure that they will work even when affected by water, tough weather conditions, ultraviolet rays, corrosive chemicals, and constant use. Call today for your custom overmolding and cable molding needs!

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