Custom Overmolded Cable Assemblies: Maximum Durability for Harsh Environments

Jiatel’s Overmolded Cable Assemblies provide the ultimate protection for critical wire-to-connector interfaces. By encapsulating the connection in a durable polymer she

ll (TPU, PVC, or PUR), we deliver extreme strain relief and IP67/IP68 waterproof sealing.

1. Solving the Failure Point: Advanced Strain Relief Mechanical failure most often occurs at the cable exit point. Unlike standard heat-shrink solutions, Jiatel’s overmolding bonds directly to the cable jacket.

• Benefit: This eliminates stress on internal solder joints and prevents insulation pull-out.

• Reliability: Engineered to withstand 10,000+ flex cycles in high-vibration industrial and medical environments.

2. Rapid Prototyping: 3D-Printed Mold Samples Why wait months for tooling? Jiatel accelerates your NPI (New Product Introduction) process:

• 8-10 Days: Receive 3D-printed mold samples to verify form, fit, and ergonomics.

• Low Tooling Cost: Cost-effective custom molds for small to medium-batch production.

• DFM Support: Free Design for Manufacturing (DFM) analysis to optimize your cable’s overmold geometry.

3. Technical Capability Comparison

4. Integrated Pogo Pin Solutions Our overmolded cables are frequently paired with Jiatel’s 2.5mm pitch pogo pin systems to create rugged, waterproof charging interfaces for EV diagnostic tools, medical handhelds, and industrial IoT devices. This “two-piece” integrated design ensures a gas-tight connection and 100% signal integrity.

5. Compliance & Zero-Defect Quality Every assembly undergoes 100% Hi-Pot and continuity testing. Our facility is ISO-certified, ensuring your cables meet the rigorous standards required for Automotive (EV) and Mission-Critical Medical applications.

Ready to start your custom overmolding project? Contact Jiatel’s Engineering Team for a response and technical review within 12 hours.

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