Assembled VS Molded Cable Assembly–What You Need to Know

Choosing the correct cable requires careful consideration, whether molded or assembled vs custom-cable assembly; insulation, conductors, and sheathing are different areas you must visit.

All these choices make or mar the performance and durability of your finished cable. Even the best-sheathed cables cannot prevent damage at the final point. After fitting a connector, that section of the cable is likely to bend, and twist more than you bargained for. Thus, for the cable’s success, a connector shell is critical.

Here, we’ll differentiate between two custom shells: Assembled and Molded.

Crimper, Cable and Connectors

Chapter 1: Assembled Cable

As the name suggests, assembled cables include many pieces that are manually assembled at the field. In some applications, plastic or metal connectors are the only alternatives. These are custom made assemblies that assure easy installation. Metals or plastic are the widely used materials for assembled cables.

Three essential factors when opting for an assembled cable are the labor, its cost, and future repairs.

Proper Installation

Assembling cables on the field demands experienced and knowledgeable technicians. To avoid installation failure, ensure the in-house or outsourced personnel test the cables at every step.

Cost

Production of assembled cables may save you a few bucks, but the labor costs add to the total. The sum brings you to close to the cost of molded cables.

Maintenance

Assembled cables offer quick and easy fixes or modifications. Since they are built using multiple components if the assembly requires any repairs, replace one component.

Black Assembled Cable

Functions:

Assembled cables serve a purpose similar to wire harnesses, and the terms are often used interchangeably. But they’re designed for diverse applications

Cable assemblies protect the interior wires and cables from several environmental hazards. The threats can be anything from moisture to heat. Contrary to molded cable assemblies, this variant offers flexibility.

The next chapter includes everything you need to know about picking the perfect molded cable for your equipment.

Chapter 2: Molded Cable

The second type of cable assemblies, the custom-molded cable contains a Polyvinyl Chloride (PVC) shell. The process of molding cables is such:

The cables enter a wire cavity with the connectors attached to them.

The mold is then injected with thermoplastic PVC and heated.

The result is a finished cable once you remove the PVC after it has cooled down.

The method remains constant, but instead of exposed terminals, you get a PVC encapsulated connector. You cannot separate the components now; the coating makes the cables solid and durable, not leaving room for alterations. Thanks to the durable coating, they last longer and even in the most extreme conditions.

Molded cable assemblies or Overmolded cable assemblies are custom-made and eye catchy. Although a vibrant appearance isn’t what customers look for when creating cable assemblies, they must. The vivid colors help to assess the cables after installation, in case a cable needs switching or replacement.

Colorful Molded Cables

Functions:

Over the last decade, Overmolding has drastically changed the appearance and functionality of cable assemblies. Molded cable connectors extend the life of your product and diminish installation errors.

If quality is your concern, Overmolding gives you premium results. It helps to enhance the performance and durability of the assembly. Materials utilized can depend on electrical, mechanical, and physical requirements. Choose proper compounds from a wide range of choices, including:

  • Polyvinyl Chloride (PVC)
  • Rubber
  • Polypropylene (PP)
  • Polyethylene (PE)
  • Thermoplastic Polyurethane (TPU)

For harsher environments, a molded cable assembly may be the best option. Overmolding offers strain relief at the exit points rather than leaving them unbounded. The process is adequate for cable breakouts or Y/J Junctions. This kind of assembly connector also works as an anchor point called cable stops. Extra protection to the exposed joints of the cable assembly in the form of seals and glands offers endurance.

To grasp the concept better, refer to this video that tells you all about a molded cable assembly.

Now, let’s move onto the next section of Assembled VS Molded Cable Assembly–The Guide to Choose the Right Type. It covers the key differences between assembled and molded cables.

 

Chapter 3: The Difference Between Assembled and Molded Cable

For both cable, there are many people confused. So, to avoid the mix-up, we’ll help you perceive the two cabling assemblies by distinguishing between them.

Difference between Assembled and Molded Cabling Assemblies

Assembled VS Molded Cable Assembly

These are all the basic factors to differentiate between the two cabling assemblies. Both the assemblies serve a specific purpose and are reliable for certain projects. Let’s discuss their pros and cons in the following segments.

For Assembled cables, three features are essential to measuring the credibility; cost, installation, and repairs. The set comes with both advantages and disadvantages.

Assembled Cable Advantages:

Their flexibility plays as a major plus point for the assembled cable assemblies. Other than elasticity, the cabling methodology boasts several advantages; these are some of them:

Cost– Assembled cables are less expensive to produce. Additionally, you may save a few bucks in the long run if any piece needs replacement.

Installation– Their heterogenous nature makes the installation process hassle-free. Experienced technicians perform the process leaving very little room for error.

Repairs– The requirements of every project are different. Designing assembled cables to suit the user’s specifications prevents elongation of cables and their bending.

Coaxial Cable Closeup

Assembled Cable Disadvantages:

Complex on-field installation sometimes becomes chaotic without experience and knowledge. To top it off the factors influence a few disadvantages:

Cost– Technicians often overlook the labor costs creating a mess during the final tally.

Installation– Improper installation may lead to performance failure humans are prone to errors.

Repairs– In case of any malfunctioning port, it becomes impossible to locate the source behind it.

Moving on to the molded cables, they come with many advantages along with a few disadvantages.

Molded Cable Advantages:

We already know that molded cables cost you more than assembled cables. Their high rate is mainly because of two reasons: customization and strength.

Installation– Since there’s no complex assembly required, there is no chance of making mistakes in the installation process. Also, the aesthetic appeal of the cables allows technicians to make easy and quick connections.

Quality– Molded cables made of high-quality compounds ensure the best cable assemblies without constant wear and tear.
Durability– Custom molds and mixtures elevate the opportunity for a durable end product.

Colorful Molded Cables in Router

Molded Cable Disadvantages:

The cost of producing the mold alone costs manufacturer’s a fortune. Imposing it on the customers becomes mandatory to avoid loss. There are certain cons associated with appealing and durable Overmolded cables, they are:

Installation– Use of multi-colored cables may lead to confusion if not marked properly.

Quality– Though the molded cables offer premium quality, some manufacturers experiment with the quality. The consequence is low quality, accident-prone connection.

Durability– Strong wires leave no room for flexibility. You cannot bend and twist these wires into custom-spaces. Getting the right sized mold causes stiffness.

In all, both the assembling strategies are spot-on with some minor shortcomings. Depending on your requirements and environmental conditions determine the correct type.

Chapter 4: How to Choose the Right Connector–Assembled or Molded Cable?

We’ve gone through the variances and vices and virtues of the different assembly types. In this part, we’ll focus on a mutual issue faced by the public working on technical projects. Choosing the right connector, it is quite challenging. But with the correct approach, they can tackle this problem seamlessly.

Two aspects, however, get an edge over others and they are cost and the situation in which the cables need assembling.

Cost Comparison

 In most cases, connectors are the cheapest commodities that projects demand. Buying the lowest-priced item isn’t the solution; it only gives rise to future problems. Compare costs and stipulations for your project and decide.

Environmental Concerns

For assembled cables, especially, environmental aspects turn into challenges. Extremities such as air pressure, moisture, and extreme temperatures threaten most ventures.

Based on your setting and budget, you can select from a variety of connectors for your project. Confusion is natural while selecting the appropriate connector that meets your requirements. The following video takes you through the basic connectors for computers, but they are valid for different scenarios.

For this reason, technicians opt to customize products with the assistance of professional manufacturers.

Types of Connectors

Chapter 5: Who Can Make Them–Assembled and Molded Cable

Assembled and molded cables have widespread applications. Naturally, many companies produce these cables. China, for example, has several manufacturers who deal with such freights. One of the front-runners is Cloom Tech, a cable assembly manufacturer.

Cloom Tech

It specializes in providing assembled cables. We also design molded cables to meet the customer’s expectations. The professional Cable Assembly Manufacturer also offers harness assembling services. Their team of highly skilled experts are quick on their feet and quickly adapt to the market’s evolving needs. Together with the customer, they come up with the best design possible for their projects.

The manufacturers deal with a variety of industries including the medical, automotive, motorcycle, and of course, electronics and engineering industries.

Bunch of Wiring Harnesses

Chapter 6: More About the Assembled or Molded Cable Assembly

During manufacturing, Cloom Tech’s experts understand your biggest concern: the cost. Managing the production fee is difficult, but with two simple factors, we’ll show you just how simple it is.

1.How Efficiently 3D Printing Boosts Your Production

Previously, we went through all the fundamental factors of the two different cable assembling types. Now let’s find out how with a modern twist, 3D Printing booms the production of molded cables.

3D Printing expedites the manufacturing process significantly, simultaneously reducing the production costs. For the rapid prototyping of molded cable assemblies, we have the 3D Printers to thank. Before large-scale production, checking the component’s compatibility using 3D printing is ideal.

It not only saves you time but also the impact of the large-scale production cost of an unsuitable commodity.

Close-up of the 3D Printing Process

2.Effective Communication with the Manufacturer

This simple point is more often than not overlooked by technicians. Communication with the manufacturer is key to reducing costs associated with manufacturing. Without instructions, the manufacturers deliver what is they think is best for your project.
If you have something precise in mind, coordinate with the manufacturer, and let them know. It significantly diminishes the chances of manufacturing anomalies in the design. Convey as much information as possible to the manufacturer to avoid errors.
Cloom Tech has professionals at your dispatch who cater to every small requirement or challenge you put forth.

Communicating Plan with Manufacturer

Conclusion:

This guide covers the two custom cable assemblies viz. Assembled and Molded Cable Assembly. Careful deliberation is a must before landing onto a decision to implement your project better. Whether assembled or injected, the type of cable assembly is critical in determining the success of projects.

Environment, cost, proper installation, and several characteristics are important. It’s what helps in differentiating between the choice of assemblies. Both categories come with certain downsides. However, the project’s requirements and surroundings control the decision. For tougher situations, the advice is to go for custom molded cables. However, where it is not a constraint, the cheaper alternative may be sufficient.

With this guide, we aim to educate our customers regarding cable assemblies meticulously. When you understand what you need, it helps us serve you better. From power cables to automobile wiring harnesses, for any assistance feel free to contact Cloom Tech.  Equipped with a wide selection of materials for your project, we offer the most satisfactory cable solution. At Cloom Tech, we strive to deliver to our customers nothing but the best.

Hey, I am John, General manager of Cloom and OurPCB.

I am a responsible, intelligent and experienced business professional with an extensive background in the electronics industry.

Reach me at sales@wiringo.com to get a quote for your projects.

Lets Cloom Suport Your Projects