IP68 Waterproof Cable Overmolding
We manufacture sealed, IP67 and IP68 rated overmolded cables and connectors direct from our factory in Dongguan, China. As a contract manufacturer rather than a trading company, we control the tooling, the overmolding process and the quality testing in-house, so your waterproof cable assemblies are built to spec and seal-verified before they ship. Send us your connector, cable and sealing requirements and get an instant quote.
Waterproof overmolded assemblies
Overmolding seals the transition between a cable and its connector or housing in a single molded body, with no gaps for water to enter. It is the most reliable way to reach a high IP rating on a cable assembly, because there are no threaded glands or heat-shrink joints to loosen or fail. Typical assemblies we produce:
- Sealed connector-to-cable assembliesFor outdoor and wet environments.
- Overmolded sensor cables and probesSealed transitions on measurement and control cables.
- Waterproof LED and lighting connector cablesSealed power and signal for outdoor lighting.
- Industrial, automotive and marine cablesSignal and power assemblies for harsh environments.
- Custom cable-to-housing entriesA molded seal that replaces a separate cable gland.
IP67 vs IP68: which do you need?
Both ratings mean the assembly is fully dust-tight and protected against water immersion. The difference is depth and duration. Tell us the depth, duration and temperature your product must survive, and we design the overmold, material and seal geometry to meet it, then verify by testing.
Deepest / longest
TPE and TPU
We select the overmold material to match your cable jacket, connector body and environment so the molded seal bonds properly and stays flexible in service. Material and hardness are chosen per application; see our TPE vs TPU comparison for detail.
- FlexibilityHigh
- Chemical & weatherGood
- Strain reliefStrong
- CostCost-effective
- Abrasion & tearHigh
- Oil resistanceHigh
- ToughnessHigh
- Best forIndustrial, automotive, outdoor
Molded seal vs glands and heat-shrink
A molded seal has no fasteners or joints to fail, which is why overmolding gives the most reliable high-IP seal in volume production.
| Sealing method | Seal reliability | Strain relief | Best for |
|---|---|---|---|
| Overmolding (molded seal) | Highest, no gaps or fasteners | Built into the molded body | Volume production, permanent sealed assemblies |
| Cable glands | Depends on correct install and torque | Limited | Field-serviceable panel entries |
| Heat-shrink and epoxy | Moderate, labour dependent | Low to moderate | Prototypes and low-volume repairs |
Built and seal-verified in-house
Every waterproof cable assembly follows a controlled flow. We run our quality system to ISO 9001:2015 and pressure or immersion test IP-rated assemblies so the seal is proven, not assumed. Tolerances and testing are documented and available on request.
Low and medium volume, custom to your parts
We build to your connector, your cable and your rating, whether you supply the components or ask us to source them. Custom tooling makes short and medium production runs practical, and design-for-manufacturing feedback is included so the first parts are right.
Waterproof overmolding questions
Can you match my existing connector?
Yes. Send the connector part number, a sample or a drawing and we design the overmold around it. If you do not have a connector selected, we help choose one that suits your sealing and electrical needs.
What is the minimum order quantity?
We handle low and medium volume runs. Tell us your annual and per-batch quantities in the quote request and we confirm the most economical tooling and run size for your case.
What lead time should I expect?
Lead time depends on tooling and volume. New tooling adds time up front, after which production runs are fast. We give a firm timeline with your quote.
How do you verify the IP rating?
IP-rated assemblies are pressure or immersion tested to the depth and duration your application requires, so the seal is confirmed before the parts leave the factory.
Which overmold material will you use?
TPE or TPU, selected to bond with your cable jacket and connector and to survive your environment. We recommend the material and hardness during design review.