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Authorized Suzhou distributor · Xinya Electronic Co., Ltd. 📞 +86 15862457677 📫 [email protected]
Xinya AWM Wire Authorized Suzhou distributor · Xinya Electronic Co., Ltd.

Over-Molded Cable Assembly | Injection Moulded Cable

Over-moulded and potted cable assemblies: injection-moulded strain relief, IP67 and IP68 sealing, low-pressure potting and keyed custom housings.

Over-molded cable assembly with moulded strain-relief boot
Made to drawing. No prices are published and there is no cart. Send the drawing, a sample or a list of from-to points and we will quote the wire, connector, crimp and test method in writing.

Over-Moulded & Potted Cable Assembly: what we build

Where a cable leaves an enclosure and enters the weather, the gland is the weak point. An over-moulded assembly removes the joint entirely: the jacket and the housing become one continuous component, so there is no compression gasket to relax and no cable entry for water to work along.

Two processes are used here. Injection over-moulding puts a PVC, TPE or TPU body directly around the cable and the terminal block, which gives the strongest strain relief and the best sealing. Low-pressure potting surrounds an open board or an exposed solder joint with a soft compound, which protects the electronics without the load a rigid mould would impose.

The jacket material is chosen for adhesion to the compound as much as for its electrical rating, which is why the wire is selected after the moulding process rather than before. Mould tooling is quoted as a separate one-off item and the first article is approved against your drawing before production starts.

How we build it

  • Injection over-moulding in PVC, TPE or TPU with keyed housing geometry
  • Low-pressure potting for open boards and exposed solder joints
  • IP67 and IP68 sealing verified on sampled assemblies before shipping
  • Jacket material selected for adhesion to the moulding compound
  • Strain relief that carries the load, not the terminated conductor
  • Mould tooling quoted separately with first-article approval

Wire we build this harness on

Every conductor is Xinya wire from this site's own catalogue, so the style inside the harness can be traced to a published data sheet. These are the lines most often specified for this application:

If your drawing names a style that is not listed here, ask — the catalogue published on this site is a subset of what the factory runs, and we can quote against a style number as easily as against a description.

How to get a quotation

Send the drawing, the sample, a photograph with a scale in shot, or a table of from-to points. Our reply names the wire style, the connector series, the crimp specification, the sleeving and the test method, so your engineers can approve the part rather than interpret a description. Nothing on this site carries a price: every harness is quoted against the specification you provide.

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Questions buyers ask about over-moulded & potted cable assembly

When is over-moulding better than a connector with a gasket?

When the joint has to stay sealed for years without inspection. A moulded body has no gasket to relax and no cable entry path; a gasketed connector relies on a compression force that changes with temperature and time.

Which wire works best under a moulding compound?

The jacket has to bond with the compound, so the choice follows the process rather than the voltage. PVC and TPE jackets bond well to their own families; where a halogen-free construction is required, the mPPE line is the usual starting point. Send the requirement and we will name the combination.

Is tooling expensive?

It is a one-off cost that depends on the housing geometry, and it stays with the part. It is quoted as a separate line so you can see what is tooling and what is production.

Can you over-mould a shielded cable?

Yes, and the shield is terminated before moulding so the moulded body does not become part of the shield path. Drain placement matters here, and it is settled at the drawing stage.

Do you make a sample before production?

A first article is produced from the tool and submitted for your approval. Production does not start until it is signed off.

Other Assembly Services harnesses

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Tell us the style, AWG, colour and quantity — or attach nothing and just describe the requirement. We reply to every enquiry.

We use your details only to answer this enquiry. No prices are published on this site.

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Questions & answers

Frequently asked questions

Certifications, lead time, payment, shipping and MOQ — the points buyers ask about most often. If something is still unclear, send us your requirement and we will answer directly. See the full FAQ →

01 Are you a manufacturer or a trading company?

We are a wire harness manufacturer — cutting, stripping, crimping, sealing and testing are all carried out in-house at our Suzhou plant. We are also an authorised distributor of Xinya brand electronic wire, so you can source both the wire and the finished harness from one supplier.

02 What certifications do your electronic wires have?

Our electronic wires carry UL, VDE, PSE and CE approvals, together with RoHS and REACH compliance for the European market; TUV approvals are available for PV and renewable-energy wire. Certificates and test reports are issued by the manufacturer and can be supplied with your quotation on request.

03 How long is the lead time?

For electronic wire, popular styles such as UL1007, UL1015, UL1061 and UL1569 are normally available quickly; other styles, non-standard colours and cut lengths usually take around 7 days. Wire harnesses are made to order, so the schedule depends on your drawing, connector availability and quantity — we confirm it in the quotation.

04 What are your payment terms?

We commonly accept T/T (telegraphic transfer), PayPal and Western Union. Typically a 30% deposit is required before production, with the balance paid before shipment.

05 How do you ship the goods?

Samples and small orders are shipped by international express (DHL, FedEx, UPS, TNT) or by air freight. Larger orders normally go by sea to reduce freight cost. We can quote EXW, FOB, CIF or door-to-door terms and will recommend the option that best fits your budget and delivery date.

06 Do you have a minimum order quantity (MOQ)?

We keep a low MOQ to support your business. Generally the MOQ is 1 piece for standard models, although it may vary slightly for customised products. Small trial orders are welcome.

07 Can you build harnesses to our own drawing or sample?

Yes. We build to print and build to sample — send us a 2D drawing, a BOM, connector part numbers or even a photo of the part in use, and we will assemble, test and quote accordingly.

08 Can I get a sample before placing a bulk order?

Yes. We are happy to build a prototype first so that you can approve the fit, crimp and finish before committing to volume. Send the drawing and the target quantity and we will quote sample cost and lead time.

09 What information do you need to give a quotation?

For wire: the style or UL number, AWG, voltage and temperature rating, insulation, conductor, colour and length. For harnesses: the drawing or BOM, connector brand and part number, terminal and housing type, wire specification, cut length and tolerance, sleeving or tubing, label and packaging requirements, quantity and destination. If anything is unclear we will ask — or propose a construction for you.

10 Do you support OEM / ODM and private labelling?

Yes. We work with customer-specified connectors and brands as well as JST, Molex and HongXing, and can add printed markers, custom labels, printed bags and your own carton artwork for OEM and ODM projects.

11 How do you control quality?

Every order goes through incoming wire inspection, cutting and stripping checks, crimp height and terminal pull-force testing, 100% continuity and open-and-short testing, and a final dimensional and visual inspection. Inspection records can be supplied with the shipment when your project requires them.

12 Can you help with wire and connector selection?

Yes — our engineers help match wire gauge, insulation and temperature rating to your current, voltage and working environment, and select a terminal and housing combination that crimps reliably. Describe the application or send a sample and we will propose a construction.

13 Can you supply cut lengths and custom packaging?

Yes. Wire can be supplied in cut lengths, coils or spools, with PE bags, cartons, pallets and printed labels arranged to suit your warehouse or production line.

14 Do you ship worldwide, and can I visit the factory?

We ship worldwide, with regular shipments to Europe, North America, South-East Asia, the Middle East and Australia. You are welcome to visit our plant in Suzhou, and you can see our production lines in the factory videos on this site.

15 What happens if there is a quality problem after delivery?

Contact us with the order or batch number and photos of the issue. We will check it against our production and inspection records and, where the fault is confirmed on our side, arrange replacement or credit.

Send us your requirement See our production lines

Need wire to a specification?

Send the style, AWG range, colour and length — or your BOM and drawing. We will come back with construction, availability and lead time. This catalogue publishes no prices; every enquiry is quoted directly.

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