0118 9325 120 sales@hcal.co.uk

Cost effective Over-Moulding Solution from Hunter Cable Assembly Ltd

Over-moulding connectors as part of a cable assembly no longer requires high volume production to cover the cost of tooling.

Hunter Cable Assembly now has the capability to supply cost effective Over-Moulding Solutions.


overmoulding prodecure

Over moulding Facts:


  • Durable, rugged design often improves mechanical reliability, e.g. resistance to shock
  • Design flexibility - Custom design of mouldings
    e.g., family of connectors or clear product range
  • Design improved ergonomics or grip to your products
  • Pcb’s and other components e.g. Ferrites can easily be over moulded
  • Once moulded the product is tamperproof and environmentally sealed
  • Overmoulding makes it easy to encapsulate fragile components
  • Overmoulding is an alternative to conformal coating
  • RoHS compliant


from design with 3D AutoCad

from design

Production of overmoulded cable and connector

through production

Finished overmpupded cable

to finished products

Low pressure moulding is perfect for Low to medium volume production 50+ units.

Low pressure moulding is a manufacturing process that sits between injection moulding and potting.


Material Facts:


  • Non toxic, single component polyamide material.
  • Moulding material has shore hardness range from 77 to 92
  • Material meets UL 94-V0
  • Material has High Dielectric properties up to 25kV / mm
  • Great adhesion to different substrate, including ABS, PVC, XLPE etc.
  • Moulding material has a temperature range -40°c to + 125°c
  • Fast cure time’s


Moulds for standard D-type connectors are already available, so production can commence in a short timescale without the need to procure tooling.

Custom tools can be designed in house and sourced within 6-8 weeks, often less. The scope for over-moulded components is enormous with the possibility of incorporating printed circuits, ferrites, multiple cable entry points to identify a few of the applications.


Tooling Facts


  • Low pressure moulding is Cost effective and less expensive than complicated injection methods
  • Over moulding has the advantage of Low start up costs compared to costly injection moulding.
  • Long tool life.
  • Precision-machined tool = high repeatability = low waste.
  • Mould bushes or other mechanical fixings easily incorporated into your design.
  • Possibility to mould strain relief or cable boots.
  • Design’s can still maintain shielding for EMC, EMI properties.
  • Option to mould company logo or part numbers.
  • Mat or gloss surface finishes.


There are many benefits of over-moulding: rugged, almost unbreakable protection; built in strain relief; cosmetically attractive; possibility of incorporating company logos.


If you would like to know more about over moulding your cable assemblies please contact us here or call us on 01189 325 120.
Alternatively you can send us an email to sales@hcal.co.uk