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.