Custom Overmolded Cable Assembly
Overmolded cables are often used to solve application issues and GCT has helped many customers overcome design problems by offering innovative solutions. Please browse the unique stories behind the products by clicking on the photo gallery. Some examples are, solving power issues by integrating a DC socket into a D Sub, solving accessibility problems by offering right angle cable mounted connectors when straight is the standard, integrating panel mounting to allow normally cable mounted components to pass through an enclosure, backfilling connectors to allow hard cable turns due a space restriction.
Whatever your location GCT's experienced sales and engineering teams will help you from concept and design through to production.
Quality is at the heart of GCT's offering, facilities are UL & ISO 9001:2008 certified. Where customers require UL traceability, GCT ensure materials and components always meet their needs. UL file number and ISO certification.
All assemblies are 100% tested guaranteeing reliability and compliance, a variety of appropriate tests are applied depending on cable assembly type. Examples are: Short or open circuit, intermittent circuit, mis–wiring. Hi-Pot, static load for strain relief, bending test, crimp pull off force, contact to housing retention force and plastic hardness.
Key advantages of GCT's overmolded product range are the low MOQs (as little as 1,000 pieces) and low tooling cost thresholds - it costs as little as $500 to develop a custom overmold. Target delivery for custom design first off samples is six weeks.
Asides from the overall look and feel of an overmolded cable assembly, there are numerous technical advantages over crimp or IDC cable assemblies. Overmoulding offers excellent durability, using a two mold – inner & outer process. Using this type of cable also enables you to integrate components, including PCB's, which offers customers a variety of design solutions.
The range offers many choices, which our photo gallery demonstrates: Coiled cables, logo printing, integrated ferrites and a huge variety of colour options (including colour matching where required).
We offer material hardness options, measured on the Shore hardness scale, for example grommets which allow cables to be snapped into a panel should be soft rubber, while durability and wear on connector overmolds may be improved by a harder compound. All types are available.
Additional options include braiding, drain wire, heat shrink and cable marking in various styles, including labels. Cable jacket and core colour options offer you a variety of choice. Assemblies may be custom packaged to meet your specifications. Environmental options, such as halogen free are also available.
Cable looms may be supplied with prepared ends, which are stripped, twisted and tinned for soldering to a PCB, you can see examples in the photos. Another option is partially stripped, otherwise known as 'slug' to allow customers to prepare twisted ends on site.
USB-A, USB-B & RJ45 LAN Sockets in one overmould cables to Overmoulded PlugsCable UL2725, USB 2.0 (28AWG 7/0.12BC) x1P+(24AWG7/0.20BC) x 2C+D(28AWG 7/0.12BC), OD 4.2mm, Jacket black PVC. Cable Cat 5e U/UTP AWG24x7/0.127(BC), black PVC jacket. Length 310mm.
Temperature sensor Cable for Medical ApplicationTemperature sensor with multilayer overmould to 6 Pin DIN connector, gold plated. N-UL [1Px30#(25/0.05TS),PE,ID0.5]x2C(Yellow/Green, White/Brown)+[1Px28#(19/0.08TS),PE,Ido.55]x1C(Red/Black)+(PTFE+16/10/0.08TCBD), Jacket PMS280 Blue PVC 3.5mm dia. L.4000mm
Custom overmould socket cable assembly12 pole custom overmould socket latching and polarized for blindmate to 30mm prepared end stripped and tinned, 11 core 7/0.2mm PVC insulation, drain wire, jacket 6.5mm PVC black L 450mm.
Box header 12 pole custom latching and polarized for blindmate applications.