There are two main options when it comes to shells for terminal connectors on your custom cable: assembled and molded.
Choosing between a molded cable assembly and one that must be assembled in the field requires careful consideration to ensure you are making the right decision for your application. When designing a custom cable assembly, there are many options for conductors, insulating materials, jacketing, and so on. All of these choices can affect the performance and durability of the finished cable. However, even the most durable cable is most likely to fail at the terminal point. The process of cutting and fitting the cable with a connector can expose it to damage. Once the terminal is in place, it is frequently the section of cable that is subject to the most twisting, bending, and other stresses. Because of this, the selection of a connector is key to determining the overall success of the cable.
As you may have guessed from the name, assembled cables consist of multiple pieces that are put together manually in the field. Connectors can have plastic or metal shells, and in some applications are the only solution. However, when you are choosing between assembled and molded cable assemblies, there are a few important considerations:
- Installation – Since cables and connectors are assembled in the field, the experience and knowledge of the technicians performing the installation is very important. Whether using in-house or outsourced personnel, you must ensure that they are properly installing and testing your cable assemblies to prevent failure due to improper installation.
- Cost – Comparing costs for assembled and overmolded cable assemblies can be tricky. On one hand, assembled cables are less expensive to produce, but you must also factor in labor costs for installations which can add to the overall expense.
- Repairs – Because these types of cable assemblies are made with multiple components, they can be disassembled for applications when it makes more sense to repair an existing cable assembly than replace it with a new one.
Molded Cable Assembly
Overmolded cable assemblies feature shells that have been created by heating a plastic or rubber material and injecting it into a mold. Because the products are custom-molded, even aesthetic elements like color can be chosen for a sleeker appearance or to help differentiate cables. Here are a few of the benefits of overmolded products:
- Customization – With the range of materials available when designing a molded cable assembly, you are able to produce a cable that is tailored to the specific environmental concerns of your equipment.
- Fewer Installation Errors – Since no additional assembly is required, a molded cable assembly can be installed quickly with a simple process that minimizes the opportunity for human error.
- Strength & Flexibility – Cables are subject to additional stresses where they exit the connectors. Overmolded components can be designed to offer additional flex and strain relief to create a cable that is more durable and less susceptible to premature failure.
Choosing between an assembled or overmolded cable assembly is an important decision that requires some careful consideration. Meridian Cable is able to produce cables with overmolded components in house, using a wide variety of materials to ensure your finished cable meets the needs of your equipment. If you’re ready to design an overmolded cable assembly, get in touch. We’d love to hear about your project!