Custom Molded Cable Assemblies
WIRES specializes in precision molded cable assemblies, providing high-quality, reliable solutions. These assemblies are ideal for specialized applications in confined spaces and extreme environments where standard wiring harnesses cannot meet performance requirements.
Our Global Wire Harness Clients
Through high-pressure injection molding, molten material is die-cast, cooled, and shaped according to the mold design. WIRES provides end-to-end services from design to production, incorporating stress-relief features at connector interfaces. Our injection-molded cable assemblies deliver durable, reliable performance across industries such as medical devices, heavy industrial machinery, and automotive applications.
Customizable Molded Cable Assembly Products
Each cable assembly from WIRES is manufactured to exact specifications, including custom lengths, performance ratings, materials, and conductor sizes, ensuring it meets your unique application requirements.
WIRES - Forming Process for Cable Assemblies
From design through manufacturing, WIRES collaborates closely with you at every stage to ensure precision, performance, and reliability in each cable assembly.
Design Review Process
WIRES begins with a preliminary design based on your cable drawings, requesting additional details as needed to ensure products meet your performance and specification requirements.
Mold Making
Based on your product drawings, we determine whether a single-cavity or multi-cavity mold is most efficient. For complex shapes or irregular contours, custom molds for multiple forms can be produced simultaneously, supporting high-volume manufacturing while also optimizing processes for single-shape products.
Material Selection
Standard materials provide versatility and adaptability for most applications. For extreme conditions such as high temperatures or specific hardness requirements, WIRES can employ specialized polyamide compounds to meet your needs.
Forming Process
Using fully automated injection molding equipment, WIRES ensures consistent, high-quality production. From material heating and process adjustments to final overmolding, our technicians provide comprehensive guidance at every step, guaranteeing accuracy, stability, and premium product quality.
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Customization Options
WIRES provides a wide range of customization options, carefully designing every detail to ensure your specific requirements and application needs are fully met.
| Connector | Cable | Materials | Characteristics | |
|---|---|---|---|---|
| Customization Options | USB, HDMI, BNC, SNA, TNC, N D-Sub (9 to 50 pins) M8/M12 Circular Connectors Molex Connectors VHDCI / SCSI Telco 25, 50, and 100 pairs (Cat 3 and Cat 5) V.35 AMP/Tyco Connectors | USB cables, coaxial cables, RF cables, I/O cables, Molex cables | Macromelt Rubber Polyvinyl Chloride (PVC) Polycarbonate (PC) Thermoplastic Polyurethane (TPU) Polyethylene (PE) Acrylonitrile Butadiene Styrene (ABS) Polypropylene (PP) etc. | Exceptional waterproof performance – compliant with IP67/IP68 standards and offers high abrasion resistance Extensive library of standard molds – suitable for various common applications Customizable branded molds – featuring logos or functional markings Pre-molding and/or overmolding – available to meet specific design requirements |
| Capability | Special release coating – ensures flawless injection molding, with custom-engineered potting fixtures Potting services – provide fully waterproof sealing Crimped and soldered joints – undergo rigorous quality inspection with 100% testing of every unit Cost efficiency – reduces costs and streamlines shipping processes Production consistency – each batch matches prototype specifications exactly | |||
| Forming equipment | Industrial-grade MoldMan thermoplastic injection molding machine – designed for high-volume production Polyamide Macromelt OM 646 – precisely heats material up to 475°F to meet application requirements MoldMan injection molding machine – provides precise molding with around 2 tons of clamping force and accurate injection timing for consistent results All China factories – equipped with full production capabilities | |||
Looking for a Reliable Custom Wire Harness & Cable Assembly Partner?
Guaranteed Quality & Safety
Compliant with IPC/WHMA-A-620 standards, ensuring reliable performance in every wire harness and cable assembly.
Customer Reviews of WIRES
Customer reviews of WIRES' custom wiring harness services
This rice transplanter solves the problem of wire harnesses breaking easily! The bent sections are protected by spiral sleeves, ensuring that the wires remain intact even after tens of thousands of twists, significantly extending the overall service life.
The lightweight design of electric bicycle wiring harness is really great! The weight has been reduced by 30% compared to the original factory, and the battery life has increased by 5 kilometers. The wiring is also particularly neat.
The Geely special wiring harness is tightly sealed, and the original plug is plug and play. The modified audio system lights up once, saving 3 hours of labor costs!
Frequently Asked Questions
Customers choose WIRES not only for the value we deliver, but also for our responsive and detailed support. Here are some of the frequently asked questions we’ve compiled.
What is the difference between single-cavity and multi-cavity molds?
Single-cavity molds – ideal for larger products, producing one part per cycle
Multi-cavity molds – designed for smaller products with high order volumes, allowing a single mold to produce multiple parts simultaneously, which accelerates production, improves efficiency, shortens delivery times, and reduces manufacturing costs
What is the difference between molded cable assemblies and overmolded cable assemblies?
- Molded cable assemblies – created by fusing cables and connectors into a single unit using hard plastic or rubber through injection molding. They are highly durable and resistant to moisture, dust, and physical stress, making them ideal for industrial, agricultural, and outdoor applications.
- Overmolded cable assemblies – involve adding a protective layer over existing cables and connectors, enhancing stress resistance (bending, torsion) while maintaining flexibility. These are perfect for dynamic applications, including robotics, medical devices, and environments with repetitive motion.
This differentiation helps OEMs select the right solution for high-stress, high-performance, and industry-specific requirements, ensuring reliability and long service life.
How does potting differ from compression molding or overmolding?
- Potting – uses epoxy resins or potting compounds, which are liquid sealants that cure over time. Potting primarily protects connectors from moisture and humid environments, providing insulation and environmental protection.
- Compression molding/overmolding – permanently fuses materials together under high temperature and pressure, creating a durable structure. While extremely strong, this method does not always provide a completely airtight seal.
This distinction helps determine the best protection method for connector reliability in different environmental conditions.
What is Shore hardness? Why is it important?
- Shore hardness measures the stiffness of materials like rubber or plastic.
- It is critical in component design: softer materials (lower Shore hardness) offer flexibility, while harder materials (higher Shore hardness) resist deformation.
WIRES helps select the optimal hardness grade for your application. Our proactive service has earned the trust of over 300 clients, delivering approximately 2 million wire harnesses to date, ensuring reliability and performance across industries.
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