Cable Overmolding

Cable overmolding is a specialized rubber molding process in which elastomeric material is molded directly onto a cable assembly, connector, or electrical harness to create an integrated, sealed enclosure. CPI applies this process to deliver robust strain relief, environmental sealing, and mechanical protection for critical cable terminations used in industrial equipment, defense systems, agricultural machinery, and energy infrastructure.

Our overmolding process begins with a thorough review of the cable assembly's geometry, connector type, and environmental exposure requirements. We then develop a custom compound, typically from silicone, EPDM, or Viton thermoplastic elastomers, formulated to bond reliably to the cable jacket material and connector housing while meeting the ingress protection ratings specified by your design. Molds are engineered with precise gating and shut-off geometry to prevent flash intrusion into connector mating surfaces.

The result is a monolithic, factory-sealed cable assembly with no adhesives, potting compounds, or separate boot assemblies required. Overmolded components dramatically reduce field assembly time, eliminate potential leak paths, and provide superior pull-out resistance compared to slip-on alternatives. We support both prototype and production volumes, with full dimensional inspection and pull-force testing available as part of our quality process.