Coiled cable assemblies with overmolded connector ends, integrated strain relief boots, and custom breakout overmolds. Overmolding adds environmental protection, mechanical strain relief, and product identity to standard coiled cable constructions.
The failure point of a coiled cable is almost always at the transition between the straight lead section and the coiled section, or at the connector termination. Overmolding this transition zone with a tapered TPE or PUR boot distributes the bending stress over a longer length, eliminating the sharp bend radius that causes premature conductor fatigue. Well-designed overmold geometry increases cable life by a factor of 3–5× in high-cycle applications.
We design and build custom overmold tooling for coiled cable assemblies. Straight and angled boots, bayonet locking features, ergonomic grip geometry, and custom brand colors are all achievable. IP67 sealing at the connector interface is standard with through-molded connector bodies.
