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Debunking Myths Around the Connector Overmolding Process

Overmolding is a well-adopted method for protecting connectors vulnerable to added stress. But misconceptions continue to circulate around the overmolding process, from the cost, to timelines, to the flexibility of customization. And with these misconceptions comes hesitation on the part of businesses to invest in this added layer of protection.

As we look into some of these myths, we’ll pull back the curtain on some of the benefits of connector overmolding that make it an even more worthwhile investment.

Connector Overmolding Comes with a Significant Price Tag


Overmolding connectors is an added expense, but not necessarily one that needs to mean paying for completely new tooling. Amerline, for instance, looks for opportunities to make minor adjustments to or modify existing molds to accommodate similar kinds of connectors. This helps avoid the high costs and lead times associated with a brand-new mold. 

Alongside minimizing upfront expenses, it’s also important to think about the impact that overmolding has on long-term costs. With greater strain resistance, overmolded cable assemblies are designed to last longer than their standard cable assembly counterparts, saving you the cost of repairs and replacement parts over the lifetime of the application. This is especially true when the strain relief design is tailored to an application’s needs.

Connector Overmolding is a Time-Intensive Process


While overmolded cable assemblies take more time to produce than standard cable assemblies, the resourcefulness of using existing molds when possible is just one step that can help reduce lead times. To further expedite the connector overmolding process, Amerline performs all overmolding work at our headquarters in Schiller Park, IL, with the cable assemblies then tested and shipped to their final destination. Domestically produced overmolded cable assemblies will arrive in your hands faster and accelerate your application to market. 

Connector Overmolding Offers Little Flexibility in Customization


While the decision to overmold connectors is based around customization, there are opportunities within that decision to further tailor the process to your application. One example of this is customizing overmolding materials for maximum performance.

At Amerline, we use a black thermoplastic compound with a UV stabilizer as our standard hot melt encapsulant in the injection molding process. Different material formulations and colors can be selected to best suit the requirements of your overmolded connector application.

Painting a True Picture of the Connector Overmolding Process


It’s well-known that connector overmolding provides added strain relief to applications. But it’s the lesser known sides of the overmolding process — its cost effectiveness, its reduced lead times, its room for customization — that give businesses more incentive to invest.

As we’ve alluded to above, the key to experiencing all of these benefits of overmolded connectors is working with the right partner. Amerline is proud to be that partner. While creating customizable watertight seals for your most sensitive components, we’ll help produce your overmolded assemblies in the most economical, efficient way possible.

Learn more about our connector overmolding process, or — if you’re ready to talk to us about your connector project — request a quote.


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