Overmolded Wire Harness

Product Introduction

With an overmolded wire harness you can accurately connect the plugs and wires. With this process you can remove the errors from the harness and you can always have a smooth connection with these harnesses. When making the harness the wires and the connectors stay inside the mold and the plastic or the cover material covers them. After this process the plastic gets cold and the harness is ready for use.

An OBD-II to serial cable used for making links between a repair tool and vehicles computer. The OBD-II plug has 16 pins to be connected to the vehicle's computer system. An overmolded splitter that plugs into various DB9 serial outputs can be split. With it you can easily use multiple ports without issues. Because of the overmolding vehicles cables, the connection system always stays still. There are also customized options available for creating exact size and shape. The outer covers are also made to resist the rough conditions.

Product Advantages

One-Piece Build

Plug and wire are made together in one step, creating a solid, single unit. No extra boots or glue are needed, removing weak points and saving time.

Complete Seal

Mold covers the plug and cable joint completely, blocking water, dust, and dirt. This helps meet IP67 ratings for outdoor or marine use.

Protected Joints

All joints are sealed inside and are safe from rust and wear. The outside layer resists cuts and scrapes, letting the overmolded wire harness bend and flex without harm.

Custom Shapes

Molds can make special shapes like angled plugs, grips, or flanges, even with a logo. This helps fit tight spaces and gives a pro look.

Fast Making

One-step molding removes extra work, saves time, and makes every overmolded wire harness the same quality.

Cable Assembly Manufacturing Process

The process starts by cutting and stripping wires to the correct length. Wires are then crimped or soldered to connectors for a strong link. The plug and wires are set inside a mold, and heated plastic is injected under careful pressure. It fills all gaps and locks parts together. When the plastic cools, the unit is strong and ready to use. This process is quicker and more accurate than older ways, giving a more durable result.

Advanced Molding Techniques and Tooling

Multi-Shot

Makes a hard inside and soft outside for better hold.

Low-Pressure

Gentle for protecting delicate electronics.

3D-Printed Molds

Used for fast test molds before mass runs.

Complex Molds

Can make shapes, simple molds cannot.

Automation

Robots load and run machines for speed and accuracy.

Multi-Cavity

Makes several harnesses in one run to save time and cost.

Material Recommendation

PE raw material

PE is a robust plastic that can handle many types of damage. It does not let water, oil, or chemicals get through, so it works well in wet or dirty places. It is also suitable for underground cables because it does not rot or break down. PE is more complex than PVC or TPU, so it can be used as a strong inner layer with a softer outer layer for extra safety. It does not get damaged by acids or salt, so it is excellent for places near the ocean, in the soil, or in areas with bad weather. This makes PE one of the best choices for hard and heavy jobs where cables must last long.

PVC raw materials

PVC is a low-cost plastic that people often use to make cables. It is soft enough to bend without breaking, which helps it last longer when the cable is moved around. PVC also slows down fire, which makes it safer to use. It sticks very well to the cable cover, so the outside layer stays in place for many years. The cover makes a tight seal that keeps out water, dirt, and even sunlight, so the inside parts remain safe. This is why PVC works well both inside buildings and outside in the open. But if the cable is bent repeatedly in the same spot, PVC can start to crack.

Connector material

The parts that connect cables to other things are made from strong materials so they can work well and last for years. Many waterproof connectors are covered in metal, often nickel-coated brass, which stops rust and damage from water. Some connectors are made from rigid plastic called nylon, which is strong but light. The outside cover of the cable needs to match the connector so the join between them stays tight and sealed. A good seal keeps water, dirt, and dust out, which helps the cable remain safe and work well.

Copper Conductors

Inside every cable, the wires that carry power or signals are usually made from copper. Copper is one of the best materials for moving power and signals because it works with very little loss. It can bend without breaking, essential for cables that need to move. Sometimes the copper is coated with tin or silver, which stops rust and makes it last even longer. This coating also keeps the wires clean and working well, even in bad weather. Copper wires help ensure that power and signals move smoothly and safely, whether the distance is short or long.

Solution

Overmolded cable assemblies fix many wiring problems by joining the connector and the cable into one strong, solid, sealed piece. This means the part is not easy to break and can last long, even if used daily. They can keep working on machines that shake, get wet, or are handled roughly. They stay reliable because there are no small, loose pins or parts that can fall apart. They are also very easy to set up. You just plug in one cable, and it is ready. This saves time and helps stop mistakes during installation. Overmolds can also have clear labels, bright colors, or custom marks to make the proper connection quick and straightforward. Because they do not break often, you spend less time and money on repairs.

M8 and M12 Circular Connectors

M8 and M12 connectors are small, round plugs in many machines, tools, and automation systems. The M8 is tiny, often with 3 or 4 pins, perfect for tight spaces and small sensors. The M12 is larger and has up to 12 pins, so it can carry more signals or power. Both types can be made in different coding styles, such as A-coding for standard sensors and D-coding for data signals. They are built to block dust and water, often rated IP65 or IP67, so they can work in tough places. When they are overmolded, the plug and cable are sealed together as one waterproof part. The smooth way the cable leaves the connector stops leaks, avoids bending damage, and helps the connector last longer.

M8/M12 Multi-Connector Cable Assembly

Some machines need more than one M8 or M12 connector in the same cable harness. Overmolding can join all these connectors into one solid block. This block is sealed to stop water from getting in and gives the whole piece more strength. The cables can be shaped to come out at different angles to fit into tight spaces in equipment. Color-coded plugs and clear labels help workers connect things fast and without mistakes. These assemblies are built to last for many years, even in tough places like factories, farms, or boats.

Waterproof Y-Splitter Housing for M8/M12

Overmolded housings for Y-splitters seal the spot where cables join together. Some use resin to fill every small gap, while others use a molded shell that fits tightly around the parts. Both styles are tested to keep out water, oil, and dust. Overmolding also makes the splitter look clean and professional, protecting it from cracks and wear.

M12 Y-Splitter Cable

An M12 Y-splitter turns one connector into two connectors. This means you can send the signal from one sensor to two different devices or controllers at the same time. If the splitter is not overmolded, the joint can be weak and let water in. Overmolding covers the split with thick, strong plastic, giving it extra strength and waterproofing. This means it can keep working well even if the area shakes, gets hit, or is exposed to rain and bad weather.

Industries and Applications

Automotive

Used for sensors, cameras, and lights. Works in high heat, around oil, and with lots of shaking.

Industrial

Connects sensors and machines while keeping out dust and oil. These are best for industrial tough situations.

Renewable Energy

Handles sunlight, rain, wind, and temperature changes. Saves energy and lets you save more.

Medical

Safe, clean plastics and seals keep things hygienic. These products keep all the tools secure and germs free.

Marine

Resists rust from saltwater and keeps working in high humidity. These are especially customized for different types of weather.

Aerospace

Meets strict safety rules and resists heat and heavy vibration. Accurately designed for high and low air pressure areas. Secure for many kinds of applications.p>

Advanced Working Process

Quality Assurance

Every overmolded wire harness is checked very carefully. 3D scanners check the exact size and shape. Electrical tests make sure each wire is connected the right way. Pull tests check that cables are strong and do not come loose. Special cameras look for any minor defects. Barcodes track the harness through every step of production so nothing is missed.

Mechanical Strain Relief

Overmolding holds the cable tight so it does not get pulled apart. It spreads out the pulling force so no one part is damaged. Special shapes in the design stop the wires from bending too much, which helps them last longer.

Design Flexibility

Overmolding can make almost any bend, curve, or angle to fit into small or tricky spaces. This means you do not need, bulky boxes. It keeps the whole system neat, easy to work with, and safe.

Future Innovations in Overmolded Cable Technology

Overmolding is changing very fast, and new ideas are coming every year. Many new types of plastics are now made from recycled waste or plants, which helps protect our planet. These new materials make cables safer for people and nature. 3D printing also makes the process much faster. In the past, companies had to wait many weeks for heavy metal molds, but now they can print light test molds in only a few hours. This lets them check the size, the shape, and how the cable will work before making an order.

Today, intelligent robots and strong machines do much of the work, so the cables are stronger and made more carefully. Soon, cables may have tiny sensors inside them. These sensors could check the heat, watch for movement, or even send information to other devices. This would turn regular cables into smart cables that can talk to different machines and work as part of a connected system.

Cost Efficiency Through Reduced Maintenance

Overmolded wire harnesses can cost more initially, but they save much money later. In a standard cable, the point where the cable meets the connector is often the weakest spot. In an overmolded wire harness, that part is covered in strong, thick plastic, so it is tough to break. This means fewer fixes, fewer replacements, and fewer times when the machines have to stop working. These overmolded wire harnesses can last for many more years compared to standard cables. This saves repair costs, lowers warranty claims, and keeps work going without delays. Some designs can be used in many machines, so you do not need to store as many spare parts. Even though they may cost more initially, they quickly pay for themselves with the money saved over time.

Why Selecting QL-Custom Technology Ltd

If you need strong and safe overmolded wire harnesses, QL-Custom Technology Ltd. is a great company to choose from. We have our own tools and machines to make the overmolded wire harnesses from start to finish, and we check each one carefully before it leaves the factory. We have helped over 300 customers in many fields, such as car parts, medical equipment, and industrial machines. We can design the overmolded wire harness, make samples quickly, and produce large amounts of waterproof and protected harnesses. When you work with QL-Custom, you get products built for your exact needs and tested to work well in real life.

Customer Reviews

"We received what we needed. Their overmolded wire harnesses are easy to use. We are satisfied with their service."

John Graham

"That's the fourth time we ordered products from them. And they always make us feel friendly and offer the best products."

Miller Hump

"Professional and friendly service with accurate products."

Chris Simon

"They deliver the products at the exact time with promised quality products. I am willing to work with them again."

Jennifer Holms

“Their overmolded harnesses are sturdy and made with top-quality materials. I have been using their products for a long time."

Jack Smith

"The Overmolded Wire harness is strong, safe, and passed all the tests. I trust this company and the helpful people who work there."