Manufacturing of electric cables with overmolded connectors

Davantech, is an over-molding factory in China. More specific, we do the custom manufacturing of electric cables with overmolded connectors, strain relief and cable splittings. It has to be said, that fabricating overmolded cable assemblies is a very specific manufacturing process. Therefore, it requires some knowledge and skills to do it correctly. As a result, the design of the product must be done in a proper way. When designing overmolded products, you have to count that the over molding sequence will determine the number of molds necessary for a single product.

Our offer: Custom made overmolded cable assemblies with connectors. Benefit from cable overmolding in China.

  • All types of electric cables with overmolded connectors, cable splittings and strain reliefs
  • Metal contact pins design and manufacturing
  • Professional overmolding service
custom overmolded power cable splitting


custom overmolded EV charging mating connector

Cable Splittings

Electric cable Splittings overmolding

Cable Strain Reliefs

custom overmolded strain relief

Manufacturing electric cables with overmolded connectors is a complex process that involves several meticulous steps, each contributing to the quality and functionality of the final product. These cables are indispensable components in various electronic devices, including computers, appliances, and automotive systems. The process begins with the selection of high-quality materials and continues through precise engineering, assembly, and testing. Let’s explore the detailed steps involved in manufacturing electric cables with overmolded connectors.

  1. Material Selection:

    The process commences with careful selection of materials, encompassing conductive wires, insulating materials, connector components and plastic raw materials. Each material undergoes rigorous scrutiny to ensure it meets the required specifications for durability, conductivity, and compatibility.

  2. Wire Cutting and Stripping:

    Conductive wires are cut to precise lengths and then stripped of their insulation. This step demands accuracy to maintain the integrity of the wires and ensure proper connectivity between components.

  3. Connector Assembly:

    Connectors are meticulously assembled, ensuring the correct alignment of pins and sockets. Skilled labor and automated assembly equipment may be employed to streamline this process while maintaining precision.

  4. Overmolding Preparation:

    Preparation of the overmolding material, typically a thermoplastic elastomer, is critical for the injection molding process. The material is heated to a specific temperature to achieve optimal flow and adhesion to the connector assembly.

  5. Injection Molding:

    The prepared overmolding material is injected into a mold cavity that encapsulates the connector assembly. Injection molding machines apply high pressure to ensure complete filling of the mold, resulting in a seamless and robust overmolded connection.

  6. Cooling and Solidification:

    After injection, the overmolded assembly undergoes cooling to solidify the material. Controlled cooling is essential to prevent warping or deformation of the overmolded part, ensuring its structural integrity.

  7. Trimming and Finishing:

    Excess overmolding material is trimmed and removed, leaving a clean and uniform finish on the assembly. Precision is paramount in this step to achieve the desired aesthetic and functional result.

  8. Quality Control:

    Throughout the manufacturing process, stringent quality control checks are performed to ensure adherence to specifications and standards. Visual inspections, continuity testing, and dimensional measurements are among the methods employed to maintain quality.

  9. Testing and Validation:

    Finished cables with overmolded connectors undergo comprehensive testing to verify electrical continuity, mechanical strength, and resistance to environmental factors such as temperature and vibration. This testing ensures the reliability and performance of the final product.

  10. Packaging and Shipping:

    Once validated, the cables are packaged according to customer requirements and prepared for shipping. Proper packaging protects the cables during transit and ensures they reach their destination in pristine condition, ready for use.

  11. Continuous Improvement:

    Manufacturers continually evaluate and refine their processes to enhance efficiency, reduce waste, and improve product quality. Feedback from customers and internal evaluations drive ongoing improvements in manufacturing practices, ensuring the consistent delivery of high-quality products.

  12. Environmental Considerations:

    Throughout the manufacturing process, environmental considerations are paramount. Efforts are made to minimize waste, reduce energy consumption, and comply with regulations governing the disposal of materials.

  13. Employee Safety:

    Ensuring the safety of employees is a top priority in the manufacturing process. Proper training, equipment maintenance, and adherence to safety protocols help mitigate risks and create a conducive working environment.

  14. Supply Chain Management:

    Effective supply chain management is essential for sourcing raw materials, components, and equipment required for manufacturing. Strong partnerships with suppliers contribute to the efficiency and reliability of the manufacturing process.

  15. Customer Satisfaction:

    Ultimately, the goal of manufacturing electric cables with overmolded connectors is to meet or exceed customer expectations. Through consistent quality, timely delivery, and responsive customer service, manufacturers aim to build trust and loyalty among their clientele.

In conclusion, the manufacturing process of electric cables with overmolded connectors is a multi-faceted endeavor that demands precision, attention to detail, and adherence to stringent quality standards. From material selection to packaging and shipping, each step plays a vital role in ensuring the reliability and performance of the final product. By embracing continuous improvement and prioritizing customer satisfaction, manufacturers strive to uphold their reputation for excellence in the industry.

The cable overmolding process.

The overmolding process is as follows: after we place the cable and contacts nicely in the mold, a layer of plastic is injected around the cable and pins after the mold is closed. To clarify, this layer is usually a soft plastic compound such as TPU or TPE. However, the basis of a connector often requires hard plastic which meets glow wire requirements.

The necessary parts to make overmolded connectors are:

  • Electric cable.
  • Gold or silver plated plated brass contact pins.
  • Shrink sleeve (eventually).
connector and cable over-molding process

Manufacturing of electric cable and multi cable.

Our trusted sub-contractor provides us with almost any custom made electric cable. Therefore, whether you need a multi cable with different wire diameters inside, or you need different wire diameters and twisted pairs at the same time, we can do it. In order to make a good price calculation, we need some specific information from you:

  • Number of cores.
  • Type of cores, section of the wires (AWG).
  • Type of shielding.
  • Twisting or no twisting.
  • Outer diameter.
  • Raw material of the shell.

Mounting of Connectors, terminals and lugs.

To manufacture electric cables with overmolded connectors, we mostly use connectors from well know brands. When requested, we will offer cheaper alternatives with very good quality. Next, we mount terminals and other accessories. Furthermore, you will always receive samples of the alternative components prior to series manufacturing. In this way you can verify the quality first.

At Davantech, we do more than manufacturing of electric cables with overmolded connectors. We master a number of manufacturing processes such as CNC machining, plastic injection molding and product assembly. In addition, we offer engineering services to our customers. In this way, we work together to determine the best manufacturing process at the best cost. Next to our services we produce a range of standard products used in industrial environments.

Drop us an email with your inquiry if you want to work with a Chinese overmolding factory :