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Our company makes each overmolded cable assembly with complete care. You can ask for a quote today to get the strong cables you need.

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製品紹介

M12 round connectors are plugs that have four or five pins. It has a rounded shape. To connect wires, machines, or tools, you can use them easily. Overmolded cable assemblies are used for many sectors to supply power and signals. These cables and the plugs should be able to resist rust and dirt to work properly. Plastic overmolding is the best and exact process we use to connect the cables perfectly. The hot plastic perfectly keeps the connector inside in this step. For exact bonding, this process is necessary. The plastic completely takes the pressure of the core cable and keeps it safe from tough uses. There is a tool that keeps the connector in the same place when the mold is filled with plastic. After it cools down, it is fully sealed. This process is vital for the cable to work in tough situations.

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Product Advantages

M12 male circular panel connectors

These M12 panel connectors are made to fix easily on panels, machines, or tools. They lock tight with threads, so they do not shake loose. They seal at IP67 level against water and dirt, keeping the joint safe and clean. The body is made of metal, often nickel brass, with gold pins that give strong and secure contact. This lets power and data flow smoothly and safely, even in rough jobs. The design is simple, so no special tools are needed to put them in. Once fixed, the panel connector can last many years without rust or loose parts. This makes them best for long and steady work.

M12 circular connectors with cables

Cables with M12 ends that are already molded give a safe, tight join right away. The molded part covers the pins and stops bends or breaks at weak points. The cable jacket runs into the connector with no gap. Custom cables can have marks, colors, or labels to simplify wiring. These ready cables save time, cut mistakes, and improve safety. They meet IP67/IP68 levels and stay strong even after many bends or pulls. Their strong build makes them perfect for outdoor gear, sensors, robots, and heavy factory tools.

M12 male and female circular cable connectors

We make cables with both male and female ends. We build male-to-female, female-to-female, or male-to-male sets. Each molded end bonds to the jacket and blocks dust, dirt, and shock. These cables can be used in robots, sensors, factory machines, cars, or boats. Each type is fully tested to make sure it works right.

Vertical Injection Molding Machine

We use upright press machines to make these cables. The mold is held straight up, so connectors and wires can be loaded easily and safely. For example, the Niigata MDV press is made for cable molding with clean control. These presses may turn the tables or hold many molds for faster work. This setup makes smooth and clean parts, with no bubbles or gaps each time. The machine runs with complete control, so every piece comes out the same. This way, each cable looks the same, feels the same, and works the same for long years. This process also makes less waste and uses less power, which is good for the earth.

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overmolded cable assembly image

Solution

Our full service covers design, mold making, and cable build. We first learn about your needs and how the cable will be used. Then, we designed the shape using CAD software and sometimes made a 3D print sample to test. We make the mold in steel or aluminum for the best strength. We pick the right material to match the cable, like PVC resin with PVC jacket. Then we inject the resin (PVC, TPU, or PU) around the joint under heat and pressure. Our team checks all steps to ensure the bond is strong and clean. We can make small samples or big runs based on need. This way, cost is low, time is saved, and quality is high.

商品詳細

We share full info for each overmolded cable assembly. This has the connector type (pin, code, body) and cable info (wire size, cover, jacket). For example, we note the copper type (like oxygen-free copper) and jacket (PVC or TPE). We also note connector parts: shells of nickel brass or steel, pins of gold brass, and sealing rings. You also get info on heat range, wire strength, and IP level. This detail makes sure the cable fits your job well.

Customized Mold

Each part uses a mold made just for that cable type. Our team designs the tool in CAD and can add marks like logos or names. Mold metal is picked by run size: hard steel for extended use or soft aluminum for short runs. We also offer low-cost 3D printed molds for early test parts. All molds are made with care to stop leaks or cracks. Some molds have many parts to form more shapes. All molds are built to give the same good part each time. This keeps all orders steady and safe.

Performance Testing

We test each cable before it leaves our shop. We check wires to see if they carry power and signals correctly. We tested the overmold cover to see if it was strong and sealed. We check the look to see if the color, size, and shape are clean. We test in water and dust to make sure the seal works. We also bent and pulled the cable many times to test its strength. Each test makes sure the cable meets its standard. We keep records to prove the quality of each batch.

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Material Recommendation

Copper

Good copper wires are key to any cable. We use pure copper with high flow for the best work. This cuts signal loss and heat. It also lasts longer and gives steady power. We use thin strands with a tin coat for flex and safe joins. The wire size is picked to carry the right power and still bend easily. This way, copper wires give both strong power and simple use.

ファイバーグラス

We use fiberglass rods to make the cable stiff. Fiberglass is hard and stops bending. It keeps the overmolded cable assembly straight near the join and adds life. But it may crack in very cold or hot places. We use it when stiff parts are needed indoors. Fiberglass adds strong support without a significant cost.

PVC

PVC is a low-cost and straightforward choice for cable covers. It is soft, bonds well to PVC jackets, and flows well in molds. For example, a PVC jacket with PVC resin makes a tight seal. PVC is good against wear, oil, and fire. But it can turn stiff in cold weather and is not best for hot weather. We use PVC primarily for indoor and low-cost jobs.

コネクタ

The joint part is often metal or hard plastic. For M12, the body is nickel brass or steel, which is strong and does not rust. Inside is a plastic ring to hold pins in place. The pins are copper with a gold coating for long life and good flow. The metal shell also stops noise and links to the shield if needed. We pick the body to match the job, like steel for sea work or alloy for light jobs. Each connector is made for safe and long use.

Industries and Applications

Automotive & Transportation

Overmolded cable assemblies for automotive sensors keep wires and the core safe in many tough weathers. These cables are used in engine sensors, brake systems, LIDAR for self-driving, and airbags. Sealed M12 connectors make sure each part works well. These cables add safety, keep cars smooth for years, cut repair costs, and stop sudden stops. This makes driving safer, calmer, and easier for drivers and families to trust.

産業オートメーション

Big factories and workshops need cables that work all day, even in dirt, oil, heat, and nonstop use. Overmolded M12 cables are used in robots, motors, sensors, and panels. The molded cover blocks dust, oil, and water, so machines like conveyors, CNC machines, printers, and packing lines keep running. These cables are also used in welding, painting, and food packing, where standard wires break easily. They save time, stop costly delays, and keep work smooth and steady.

医療機器

Hospitals need cables that are clean, safe, smooth, and sealed. Medical overmolded cable assembly solutions are used in heart monitors, X-ray tools, ultrasound probes, and surgery systems. The molded layer makes the overmolded cable assembly soft, smooth, easy to clean, and strong. It resists strong cleaners and bends many times without damage. Doctors and nurses can trust these cables when treating patients. They can be cleaned and reused daily, saving money and keeping patient care safe.

Aerospace & Defense

Overmolded cables protect gear in harsh places. They are used in drones, satellites, tanks, radar, and jets. They follow strict MIL rules for safety. The molded cover blocks water, dust, and shaking during flights or missions. These cables keep planes, ships, and vehicles working safely in every use.

Telecom & Networking

Modern data networks constantly need fast, clean, and stable signals. We make overmolded Ethernet cables and USB cables that keep speed strong. M12 D- and X-coded Cat6A cables work in smart factories and can bend thousands of times on robots while sending fast data. They resist oil, dust, and sunlight. We also design custom USB and Ethernet cables for outdoor use, ships, or smart city towers. These cables last for years and keep the signal speed without a drop.

Energy & Utilities

Overmolded cables are especially made to resist water, dirt & rust. These waterproof overmolded cable assembly IP67 models deliver safe data and power in storms, heat, or sea spray. Wind turbines use them in blades high above ground, and solar plants use them in vast fields. They give a steady flow of power day and night and help clean energy run smoothly without breaks.

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Steps We Apply to Make Overmolded Cable Assembly

Consultation & Design

We learn your needs and check your plans. We pick the best M12 connector and the right cable. Our team makes a 3D model and may print a sample so you can see how it looks and fits. Then we pick the right plastic, like PVC or TPU, and make a complete plan. Every step is shown to you for approval.

Prototype & Tooling

We built a sample with 3D-printed molds to test fit and function. After the tests, we made the final mold with strong steel or aluminum. This mold holds the overmolded cable assembly in place so the overmold forms right each time.

Material Prep

Wires are cut, stripped, and set in the mold. Connectors are fixed and checked. Each wire is tested before moving forward. Nothing goes ahead unless it is correct.

Injection Overmolding

Heated plastic flows around the overmolded cable assembly and connector inside the mold. For soft or small parts, we use low-pressure overmolding to keep them safe. The plastic fills all spaces and makes a hard cover that blocks water and stress.

Cooling & Unmolding

When the plastic gets hardened and the mold is cooled and ready to open, then it opens. The cable is taken out, trimmed, and shaped. Extra boots or rings may be added for strength.

Finishing & Assembly

More support is added if needed. Each overmolded cable assembly is cleaned, labeled, and color-coded. We check each one for a smooth look and good shape.

Testing

Each overmolded cable assembly is tested for power, safety, and signal. Bad ones are removed. Good ones are marked with numbers for tracking. This makes sure only safe cables ship.

Delivery

After all that, the harnesses get carefully packed and shipped to you. They come ready to use with clear marks and colors. You get safe, complete, and long-lasting color-coded overmolded cable assemblies.

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Resistance to Water, Vibration & Chemicals

Waterproof (IP67)

These cables are safe from dust and water. Molded covers seal all gaps. For example, NorComp's M12 cables are tested by spray and dunk. They stay dry in rain or water and keep devices safe.

Vibration & Shock

The molded layer acts as support. It stops wires from breaking when pulled or bent. It keeps the link tight, so signals are not lost. This makes them great for robots, engines, or trucks on rough paths.

Chemical & Oil Resistance

We use plastics like TPU that fight oil, sun, acid, fuel, and cleaners. Metz Connect's M12 cables show how they last in oily or sunny areas. Many are also fire safe. They handle fuels, washing, and strong cleaners with no harm.

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Design Flexibility & Automated Overmolding

Custom Shapes & Colors

The molded cover can be made in many colors and shapes. Bright colors add safety or match brands. Logos or marks can be molded in for ID. This makes cables easy to spot in big systems.

Multiple Connector Codes

We support many codes, like M12 A, B, D, X, USB-C, and more. You can pick what you need. We also make mixed cables, like USB to M12, to link old and new systems.

Length and Function

Cables can be made at any length. We add shields, colors, or matched ends to stop mistakes. This makes linking fast and easy.

Quick Prototyping

With 3D-printed molds and fast tools, we make samples in days. This lets you check before completing builds. Our quick prototyping overmolded cables saves time and cuts risks.

Automated Overmolding for Consistent Quality

We use automated machines to build each cable the same way. The machines check heat, pressure, and flow. Robots load and unload molds. Each step is watched for quality. This keeps cables free of errors and saves time. Each batch comes out strong and the same.

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Case Studies: Success in Real Use

Automated Doors and Transit

A rail firm needed safe door sensors for trains. We gave them IP68-rated M12 cables. They survived dirt, rain, and shaking and continued to work for years. The doors stayed safe with no stops.

Industrial Ethernet Networks

A factory used Cat6A M12 cables for nonstop data. The cables bent many times, but kept their speed. They resisted dust, oil, and sun. The factory had no delays and smoother work.

医療機器

A hospital used our cables in patient monitors and X-ray tools. After many cleanings and bends, the cables stayed soft, sealed, and firm. They passed strict safety tests.

Energy Sector

For sea wind farms, we built IP67 cables that resist salt, spray, and strong winds. They kept sensors safe and running nonstop. These gave steady, clean power with no breaks.

Request an Overmolded Cable Assembly Quote

QL-Custom Technology Ltd. is a trusted maker of safe, strong, and custom overmolded cable assemblies. We use innovative but simple designs, clear steps, and modern machines to build cables that last a long time. Our team knows how to make cables that keep working even in hard places like factories, cars, or outdoors. We look at every small detail so you always get what you need. From small test runs to big orders, we work in one place, making it easy and fast. We also make medical cables, car sensor cables, and USB and Ethernet cables with overmold. We follow strict safety rules and test for quality. From your first idea to the last step, we guide you. Contact us now for a quote and see how we make overmolded cable assembly work simple, safe, strong, and kind to the earth.

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Customer Reviews

The order was easy, and the cables matched well. Each was tested and had the right colors. The wait was not long. I will order again.

Emma Johnson

These are very strong cables. We use them on farm tools in rain, mud, and shaking. The seal is tight, and they still look new after months outdoors.

Anthony Ricci

Best cables for outside use. We used them in resort lights. They held up in salt, rain, and sun. Very strong build.

Nina Gomez

The quote and order were fast and easy. We got a full plan in one day. The cables are top quality with a smooth finish and tight seals.

Robert Zhang

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