Over the last few decades, overmolded cable assemblies have become the new standard in the industry, rendering conventional cable assemblies obsolete. But what are they? And what benefits do they offer? Let’s find out!

What are Overmolded Cables Assemblies?

Overmolded cables are assemblies that allow a wire and connector to seamlessly connect into a single part. There are a series of steps that are followed during the production of overmolded cable assemblies, including pre-molding, potting, and overmolding, the latter being the most important one.

That being said, the process of overmolding is pretty straightforward: a molten material is injected into a molten cavity and cooled down after it turns into the desired shape so it can solidify. While simple designs can be made without a hassle, complex designs may require extra consideration.

Important Things to Consider

Before the production process of a cable assembly is commenced, a comprehensive review of the assembly is undertaken to ensure that it meets the requirements laid out by the client.

This review determines the best process for each cycle of the manufacturing process.

Furthermore, it also helps ensure that the final product is abrasion-resistant, waterproof, and offers solid electrical performance.


Overmolding cable assemblies provide a multitude of benefits over conventional cable assemblies. Due to the injection molding process, they provide a higher level of functionality. Here are some of the key benefits:

  • They’re impervious to fluids, which provides extra protection when they’re exposed to harsh conditions.
  • They’re more durable and can withstand vibrations and shocks without sustaining any damage.
  • They’re more aesthetically appealing, enabling the inclusion of trade names and corporate logos.
  • They provide more reliable performance and reduce design restrictions.
  • They provide improved strain relief and flexibility
  • They enhance the total lifetime value of the cable

Final words

Overmolded cable assemblies offer great value addition. The 360-degree strain relief results in better pull strength and additional flexible support. It also helps in safeguarding the exit cable from abrasion and harsh external conditions. In addition to that, it amplifies the Electro-Magnetic Interference (EMI), providing an additional layer of protection, making it an ideal choice for a cable assembly.

Looking for high-quality overmolded cable assemblies, contact Instruments. We’re a Canada-based oilfield instrumentation manufacturer and provider that offer premium quality overmolded cable assemblies and other oilfield instrumentation, including tong line pull indicating systems, coil tubing gauge, deflection weight indicators, electronic gauges, and trash pump parts at competitive rates. To find out more, call us at 780-955-8998 or visit our website.

Leave a comment

Your email address will not be published.