Connector Insights from iCONN

What is overmolding?

Simply put, overmolding is an injection molding process in which two or more materials are used to combine the wire and connector to create a single part. To do this, the cable assembly is placed inside a mold. The first material (the substrate) is covered by the other materials in this process. The overmolding process requires a rigid plastic component to be overlaid with a TPU layer or other overmold materials using either the insert molding (a single shot) or multiple-shot molding (two-shot) technique.

Overmolding or overmolded cables are full assemblies that combine the wire and connector into one single, seamless piece. To do this, the cable assembly is placed inside a mold. Next, a molten plastic material is injected into the mold cavity. Once the plastic material cools and solidifies, it conforms to the shape of the mold and encapsulates the junction point between the connector and wire.

When looking for a manufacturer to continue producing your OEM products, not just any partner will do. Several critical factors will directly impact your bottom line for better or worse, depending on which manufacturer you choose. Among these factors is the type of internal production model a manufacturer uses to process orders. The answer you’re looking for is cellular manufacturing. Here’s why:

Far more goes into the manufacturing of overmolded cable assemblies than meets the eye. Paired with the countless suppliers who claim to be “the best” resource for your electrical needs, it’s easy to understand why so much misinformation circulates the internet regarding the cost, parameters, and importance of overmolded cables. Today, we’re addressing four of the most frequently-referenced misconceptions and setting the record straight so that your development team can make the right choices moving forward.

Molded cable connectors can have a significant impact on the quality of your product. Using a low-quality or faulty cable connector for your product is like sawing off the leg of a table: it may still look like a table, but it surely won’t function as one. Despite how crucial the electrical connection is to your electronic device or equipment, most product developers don’t know much about them. Consider today your lucky day! Here’s a quick rundown of six important details you should keep in mind when choosing an interconnect solution for your next project.

From radios and cell phones to kitchen appliances and televisions, electromagnetic (EM) energy is all around us. Below is a diagram of the Electromagnetic Spectrum, which illustrates the full range of radiant energy. The shorter the wavelength becomes, the higher the frequency and the more dangerous the radiant energy. Despite claims, there is no conclusive evidence to suggest that exposure to low-frequency EM radiation is dangerous to humans. However, even radio waves can have a menacing impact on electrical equipment.

Did you know that rapid prototyping shortens production time by an average of 63 percent? With that kind of time-to-market acceleration, it’s no wonder the future of product development depends on this technology. If your competitor incorporates rapid prototyping into their production process and you don’t, it’ll be nearly impossible to keep up with their speed and quality output.

If you're wondering what it means to have your product UL listed, the answer is pretty simple. When your product is UL Listed, it means it meets the standards for safety required.

UL is short for Underwriters Laboratories, a nationally recognized, independent nonprofit organization dedicated to product safety testing. Over the decades, this organization has become the global go-to for independent product safety certification and tests millions of products and product components every year.

When a product is “UL Listed”, that means UL has rigorously tested and confirmed that the product meets all of their stringent requirements. Upon certification, products are added to the organization’s Online Certification Directory and are privy to numerous other advantages.

Here’s why getting your product UL Listed is highly recommended.

Product development teams are tasked with two sets of goals: those that relate to product quality and performance, and those that relate to the business of product development. These goal lists may vary depending on the type of product, but every team ultimately strives for the same things — low cost, high quality, and fast to-market times. Unfortunately, speed doesn’t always lead to a quality product. That is, unless you have the right technologies and tools in place. Below are five new product development tools that will bring greater agility and efficiency to your new product development strategy process. By learning to harness the power of new technology, your team can better balance cost and speed without compromising quality.

Using standard electrical systems in extreme applications is like driving a race car over 200 mph in the dead of summer without a roll cage, seat belt, cool suit or helmet. All this safety equipment is designed to keep the precious cargo inside (i.e., the driver) protected from internal and external dangers. Likewise, electrical components that operate in extreme environments need extra layers of protection, such as overmolding.

Your product development strategy is critical to your success. Why? When designing and engineering a new product, the devil is in the details.