Custom designed, over-molded medical connector

Over-molded Molex connector

Ultrasonically welded electronic
sensor with molded strain relief

Molded 'T' junction or cable junction

Molded Components

Overmolding is the process of surrounding a component with plastic. At Meridian Cable, we have experience with designing and producing overmolding for many different industries and applications. Our inventory of over 5,000 molds means our customers have a wide variety to choose from. If you have an item that you want over-molded, let us show you how it can be done.

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Customizable Features

Enclosure Strain Relief

Electronic cables are susceptible to failure at the sharp exit point from an enclosure. Meridian has designed thousands of strain relievers for enclosures to ensure the cable is protected from bend failure.

MATERIALS

  • Polyvinylchloride (PVC)
  • Polyurethane (PU)
  • Thermoplastic elastomer (TPE)
  • Thermoplastic polyester elastomer (TPEE)
  • Thermoplastic vulcanizate (TPV)
  • Silicone

The hardness or softness of each material can be varied.

Connector Strain Relief

Connectors are often “high cycle” components in an assembly. Meridian is an expert in designing connector strain reliefs, and we have thousands of existing molds. Strain relieving the cable exit from a connector is critical to avoid conductor failure.

MATERIALS

  • Polyvinylchloride (PVC)
  • Polyurethane (PU)
  • Thermoplastic elastomer (TPE)
  • Thermoplastic polyester elastomer (TPEE)
  • Thermoplastic vulcanizate (TPV)
  • Silicone

The hardness or softness of each material can be varied.

Cable Breakouts

Whether they are called breakouts, “Y” junctions or “T” junctions it is often necessary to overmold the point where conductors leave a cable. Meridian has designed these breakouts for medical, industrial control and military applications. We also have existing tooling that may work for your application.

MATERIALS

  • Polyvinylchloride (PVC)
  • Polyurethane (PU)
  • Thermoplastic elastomer (TPE)
  • Thermoplastic polyester elastomer (TPEE)
  • Thermoplastic vulcanizate (TPV)
  • Silicone

The hardness or softness of each material can be varied.

Seals and Glands

Cable assemblies are often used in harsh environments. In such applications a seal or gland is necessary to ensure unwanted substances stay out of the enclosure. Meridian has designed overmolded seals and glands for video security, military and recreational applications.

MATERIALS

  • Polyvinylchloride (PVC)
  • Polyurethane (PU)
  • Thermoplastic elastomer (TPE)
  • Thermoplastic polyester elastomer (TPEE)
  • Thermoplastic vulcanizate (TPV)
  • Silicone

The hardness or softness of each material can be varied.

Cable Stops

Many times cables are treated to great force during use. It is critical that this force not be transferred and cause a connection to break. At Meridian we are experts in designing cable stops to transfer this type of force to an anchor point to make sure connections are not compromised.

MATERIALS

  • Polyvinylchloride (PVC)
  • Polyurethane (PU)
  • Thermoplastic elastomer (TPE)
  • Thermoplastic polyester elastomer (TPEE)
  • Thermoplastic vulcanizate (TPV)
  • Silicone
  • Brass
  • Stainless steel

The hardness or softness of each material can be varied.

Conductor Sizes

We can extrude conductors as small as 34 gauge and as large as 12. These can be combined to create a mixed gauge cable, so if you need to carry power while also delivering signals this can be combined into one cable.

SIZES

  • 34 awg
  • 32 awg
  • 30 awg
  • 28 awg
  • 26 awg
  • 24 awg
  • 22 awg
  • 20 awg
  • 18 awg
  • 16 awg
  • 14 awg
  • 12 awg

We can also do odd sizes such as 13 awg, 19 awg, 23 awg, 29 awg

Conductor Colors

We make cable with many conductors – sometimes well over 50. To keep track of the conductors, we can use different colors. We can also “mark” the cables in other ways – with stripes, dashes or even text – to ensure the right conductor goes to the right spot.

AVAILABLE COLORS

  • black
  • white
  • red
  • green
  • brown
  • blue
  • orange
  • yellow
  • purple
  • gray
  • pink
  • tan
  • white/black
  • red/black
  • green/black
  • orange/black
  • blue/black
  • red/white
  • green/white
  • blue/white
  • orange/red

Stranding Sizes

Your conductors can be made with stranding as small as 0.002 inches (0.05mm) which is excellent for hi-flex, supple cables. If you just need a standard power conductors we can use stranding as large as 0.01 inches (0.25 mm). Stranding can be bare copper, tinned stranding, tinned conductor or even plated with precious metals such as silver for increased conductivity.

SIZES

  • 0.002″
  • 0.003″
  • 0.004″
  • 0.005″
  • 0.006″
  • 0.007″
  • 0.008″
  • 0.009″
  • 0.010″
  • 0.013″
  • 0.016″
  • 0.020″
  • 0.023″

Conductor Insulation

The first protection in any cable is the conductor’s insulation. We use the range from basic PVC, PE or PP. We also use insulating materials such a natural rubber, PU, TPE, PTFE (Teflon®) and silicone.

MATERIALS

  • Polypropylene (PP)
  • Polyethylene (PE)
  • Polyvinylchloride (PVC)
  • Thermoplastic polyester elastomer (TPEE)
  • Polytetrafluoroethylene (Teflon®)
  • Silicone

The hardness or softness of each material can be varied.

Fillers

To make a cable perform its best it is often necessary to include fillers inside the cable. We use materials from basic cotton to nylon to Kevlar®. Each material is custom matched to the applications requirement to ensure proper performance.

  • Cotton
  • Nylon
  • Kevlar®
  • PVC
  • Fleece

Wraps and Shields

Often a cable’s conductors need to wrapped or shielded. Hi flex cables requirement a soft barrier between the conductors and outer jacket to prevent abrasion. Many electronic cables need shielding to prevent RFI or EMI interferance. We use materials such a fleece, cotton and aluminized mylar, amongst others, to create a cable that will match the operating environment.

  • Aluminized mylar
  • Cotton
  • Fleece
  • Spiral wrapped stranding
  • Braided strainding
  • Polyester tie. This is typically wrapped with spiral overwrap.

Jacket Materials

The final barrier between the environment and the inside of your cable is usually its jacket. This final covering acts as an insulator, a shield and protective cover. For your cable we can use materials as simple as PVC or as robust as natural rubber, Teflon® or silicone.

MATERIALS

  • Polyvinylchloride (PVC)
  • Polyurethane (PU)
  • Thermoplastic elastomer (TPE)
  • Thermoplastic polyester elastomer (TPEE)
  • Thermoplastic vulcanizate (TPV)
  • Polytetrafluoroethylene (Teflon®)
  • Silicone

The hardness or softness of each material can be varied.

Cable Types

There are many standard cable types. The cable standards help designers choose a cable with known specifications instead of creating one from scratch. These standards can also be used a building blocks for more complicated designs.

CABLES

  • TPT
  • SP-1
  • SPT-1
  • SP-2
  • SPT-2
  • SP-3
  • SPT-3
  • TS
  • TST
  • SV
  • SVE
  • SVEO
  • SVO
  • SVT
  • SVTO
  • SJ
  • SJE
  • SJEO
  • SJEOW
  • SJO
  • SJOOW
  • SJT
  • SJTO
  • S
  • SE
  • SEO
  • SO
  • SOOW
  • ST
  • STO
  • STOOW
  • HPN
  • HSJ
  • HSJO
  • HS HSO

These can be made in many different gauge configurations.

UL Certified Wire & Cable

There are many standard UL cable types. UL standards help designers choose a cable with known specifications instead of creating one from scratch. We are certified by UL to produce many standard types of wire and cable.

WIRE

  • 1007
  • 1032
  • 1095
  • 1533
  • 1571
  • 1015
  • 1061
  • 1185
  • 1569

CABLE

  • 2029
  • 2464
  • 2562
  • 2725
  • 2833
  • 2919
  • 2992
  • 2096
  • 2468
  • 2661
  • 2733
  • 2835
  • 2990
  • 20080
  • 2405
  • 2560
  • 2689
  • 2789
  • 2991
  • 20276

These can be modified for color and stripping and still be UL certified.

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QUOTE

from Meridian

  • Coax, Twisted Pair, DC Power, Coil Cord, Custom
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