Overmolding plays a critical role in the durability and performance of custom cable assemblies and connectors. By molding a protective material over the cable-to-connector interface, overmolding improves strain relief, environmental resistance, and overall product longevity.
At iCONN Systems, material selection is an important part of the engineering process when designing overmolded cables and cable assemblies. Two of the most common overmold materials used in cable assemblies are Thermoplastic Polyurethane (TPU) and Polyvinyl Chloride (PVC). While both materials offer advantages, they perform differently depending on the application and environmental conditions.
Understanding these differences helps ensure your cable assembly performs reliably in its intended environment.
Overmolding is the process of molding a secondary material over an existing component, typically where a cable meets a connector. This creates a unified component that improves:
The overmold material plays a significant role in determining how well the cable assembly performs under mechanical stress, environmental exposure, and long-term use.
TPU is a high-performance elastomer known for its toughness, flexibility, and resistance to harsh environments. It is commonly used in rugged industrial cable assemblies and overmolded cables where durability is essential.
These properties make TPU a strong choice for cable assemblies used in demanding environments.
Although TPU typically has a higher material cost than PVC, it often provides longer service life in challenging conditions.
PVC is one of the most widely used materials in cable assemblies due to its affordability and ease of processing.
PVC works well in environments where cables are not exposed to extreme flexing, abrasion, or harsh chemicals.
PVC offers dependable performance in controlled environments but may require additives when used outdoors due to moderate UV resistance.
When choosing between TPU and PVC for overmolded cable assemblies, engineers typically evaluate several performance factors:
| Property | TPU | PVC |
|---|---|---|
| Cost | Higher | Lower |
| Flexibility | Excellent | Moderate |
| Abrasion Resistance | Excellent | Moderate |
| Chemical Resistance | Strong | Moderate |
| Low Temperature Performance | Maintains Flexibility | Can Become Stiff |
| UV Resistance | Good (UV-stabilized grades) | Moderate |
Selecting the right overmold material depends on several factors, including:
For rugged environments, high-flex cable assemblies, or outdoor applications, TPU is often the preferred material. For general-purpose cable assemblies where cost is a major factor, PVC remains a reliable solution.
At iCONN Systems, we specialize in designing and manufacturing custom overmolded cables and cable assemblies engineered to meet the performance demands of industrial applications. Our engineering team works closely with customers to select the right materials and ensure reliable long-term performance.
If you're evaluating materials for your next overmolded cable assembly, our team can help guide the selection process and develop a solution tailored to your application.