Overmolded Cable Assemblies

Because they're made using multiple layers of material surrounding the cable and connectors, overmolded cable assemblies are highly durable equipment components. The extra barrier from the elements and their tough nature make these assemblies an excellent option for outdoor facilities or challenging environments like industrial complexes. 

The protective layer of plastic on overmolded cables serves to defend the conductors and connections from typical wear and tear while guarding them against the elements. Because of this added durability, these cables can stand up to rigorous tests and harsh conditions. Meridian builds overmolded cables to be rugged, long-lasting, and reliable no matter what the situation or application. You can count on our custom overmolded cable assemblies to endure everything you can throw at it.

Pulling, bending, and other stressors are the enemy of secure connections. The additional strength added to overmolded cable assemblies helps defend against excessive bending or flexing at various areas of the cable. This significantly extends the cable’s lifespan and reduces the likelihood of signal interference from bent cables, broken lines, or damaged connectors. 

Strain relief is a critical aspect of overmolded cable assemblies used in portable equipment, like military operations or medical facilities. In industries requiring constant movement or rearranging, every bit of toughness and durability counts. The last thing you want is fragile or easily broken cable connections when you're in a hurry. Because overmolded cables have built-in strain protection, they can be trusted time and time again.

Dust, moisture, chemicals, and physical damage can hinder consistent connections and secure data transfers. Dust and moisture can not only interfere with secure connections but can cause data loss and corruption. While these elements can threaten any workspace, they are especially common in outdoor facilities, industrial complexes, medical buildings, and military operations. Protection from harmful elements is an essential aspect of overmolded cable assemblies. 

With our superior manufacturing quality, we create over-molded cables that repel dust, moisture, and debris so that you can count on your connections day in and day out. We understand the importance of your signal and data. We design and create overmolded cable assemblies to maintain signal integrity, prevent data corruption, and avoid contaminating sensitive environments.

Naturally, one of the best benefits of working with Meridian Cable is the complete customization we offer. Our top-notch design engineers will work directly with your team to determine exactly what you need from your overmolded cable assembly. You have the option to choose from over 5,000 unique elements and components to build your connection project to the most exacting detail. 

With the freedom to completely customize your cable assembly, you have the option to incorporate unique overmolding materials, conductors, connectors, and so much more. If you want to incorporate custom conductor colors to identify each cable quickly, we can make that happen. If you need specialized connectors, we have you covered. Our design team will build your cable assembly your way to integrate seamlessly with your equipment and your environment.

In situations where there is constant movement or high-volume activities, vibration can cause disconnections, unstable signals, and instability. Our overmolded cables help counteract these variables, reducing the risk of mechanical failure or signal loss. Our team works with you to design cables to suit your needs environmentally and mechanically. 

Reducing vibration is essential for increased reliability and consistent signals for industries that utilize heavy equipment, such as construction, sound gear, or military applications. Not only do our overmolded cable assemblies help prevent mechanical fatigue, but they also help maintain electrical integrity, prevent signal interference, ensure safety, and maintain performance within harsh environments. In other words, we create our overmolded cable assemblies to help prevent the damage that can be caused by excessive vibration and noisy environments.

Of course, you know we can customize just about anything in your cable assembly. One way to avoid misconnections and remain organized is by color-coding your conductors and molded components. We offer unique color combinations and patterns to easily identify each cable within the assembly based on your preferences and connection needs. While this may seem like a minor feature, organizing your cable assembly through color coding can save time and hassle when it comes time to integrate your system. 

However, the benefits of color coding your cable assembly go beyond mere organization. When your cables are specifically organized and color-coded, this foolproofs them from misconnections, which could lead to damaged or destroyed electrical equipment. In fact, managing your cable assembly could save thousands of dollars in easier cable maintenance, as well as safeguarding against incorrect integration and misconnections. 

Enhanced Sealing 

In environments where a high degree of ingress protection (IP) is necessary, overmolded cables can help protect connections and prevent signal erosion with superior ceiling glands. Our enhanced sealing method for our overmolded cable assemblies helps increase reliability in harsh environments, extends the cable's lifespan, prevents insecure connections, and protects your equipment from environmental hazards. 

In applications like the medical field, hermetic sealing is absolutely essential. A proper seal ensures the safety of patients and caregivers and a safe work environment for medical equipment. When you can rely on the cable’s seal, you can help prevent potential hazards arising from loose or faulty connections.

Additional Electrical Insulation

Overmolded cables have a unique layer of protection that provides additional electrical insulation for connections. The molded components help ensure proper current flow, low signal loss, and consistent connection. This feature promotes safety and reliability for your workers and equipment. This can be especially handy in areas where moisture could potentially interact with equipment or your cable assembly. 

Naturally, the insulation grade depends on the materials you choose for your overmolded cable assembly. Fortunately, we offer a wide range of materials to choose from, so you can adapt your cables to your equipment, work environment, and budget. We can tailor your connection solution to your specifications and include any protection you need.