Cable harnesses are multiple cables bundled together to form a bunch that keeps the workspace neat and organized, and free from risks and hazards of shock or fire. Such cable harnesses also protect the cables within from the effects of abrasion, vibration, and moisture; thus increasing their lifespan and durability.
But, what are overmoulded cable harnesses? Now, you would say that they are cable harnesses that are moulded more than required, wouldn’t you? But, no. This is not what describes overmoulded cable harnesses. In fact, overmoulded cable harnesses are complete harnesses that seamlessly combine the wire and connector into one single part. The process of creating such overmoulded harnesses involves injecting a molten material into a mould cavity that conforms to the desired shape when cooled. This mould cavity could be a simple design with no markings, or a complex design with markings including company name, company logo, flanges, etc.
Now, you would wonder why overmoulded cable harnesses are used. It is because they add value to your application by providing 360° strain relief, flexible support at the cable exit, and increased pull strength. And, just like a simple cable harness, overmoulded cable harnesses also offer protection against harsh environments like abrasion, vibration, and moisture. But, along with that, they also offer increased electromagnetic interference performance.
The process of overmoulding requires certain tools, which can be designed as either straight, right-angled, or any exit required for a custom application. The material used for overmoulded cable harnesses can be colour coded to match the cable jacket or the equipment that it will be used on. Generally, materials like rubber, polycarbonate, PVC, santoprene, ABS, and macromelt are used.
When you want a customized overmoulded cable harness, you need to work with professional cable harness manufacturers in India to indicate all the details of your application and requirements. The manufacturer will review each and every detail, and determine the best materials and processes to be used at each stage of the manufacturing cycle, which includes premoulding, potting, and overmoulding. There should be a perfect mix of waterproofing, electrical performance, and abrasion resistance; and the end result should be able to surpass customer expectations.
Miracle Electronics is one of the most trusted cable harness manufacturers in India, who manufactures an amazing range of harnesses, each of which are tested for dimension, weight, continuity, high pot, pull test for verifying the production processes. Moreover, they are also checked for compliance to the environmental requirements that are to be used in. To add to that, all the production processes are certified for quality to ISO 9001, AS9100C; and the quality of the cable harnesses are certified and approved by DGAQA and MSQAA for platform specific applications. Thus, you can always rely upon Miracle Electronics as standardization is one very important aspect of our products, which is a necessity for every application. You can get in touch for all kinds of cables, cable harnesses, EMI shielded harnesses, flat harnesses, RF harnesses, ribbon harnesses, airborne looms, and military looms.