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What is a Cable Assembly?

Many different technologies are making the world wireless, but we are still dependent on cables to keep our digital world running. Circuits, cables, and cords are used in many devices and are necessary for forming essential components of every electromechanical assembly, cable assembly, and harness. Moreover, as a critical element of the electronic items, cables and cords heavily rely on injection molding for the production of affordable and efficient cable assemblies. In this blog, we will discuss injection molding, its benefits, drawbacks, uses, and importance.

How Plastic Molding Works

Plastic molding processes start by forming a mold as per the final product's design. Then, the mold is designed through 3D printing, computer numerical control (CNC), or electrical discharge machining (EDM). Thermoplastic resins are used as raw materials and are heated to a molten plastic phase and then injected into the mold. Once the cavity is filled, it is left to cool until the part solidifies.

Types of Plastic Molding

With plastic molding, manufacturers can produce products that are not only visually stunning, but also customizable. This process allows them to change their color or finish according to their brand while maintaining properties like electrical conductivity so that way they can be modified depending on need. The following are common types of plastic molding.

Vertical injection molding: In vertical injection molding, plastic is injected vertically into the mold. As the mold is placed below the injector, it allows the plastic to flow into the mold and cover every corner.

Horizontal injection molding: In horizontal injection molding, a mold is placed horizontally in front of the injector, filling the mold with plastic. It is best suited for cylindrical objects.

Insert molding: In this process, coaxial cables are allowed to be placed inside the mold when the plastic is injected, simultaneously surrounding the cables and holding all associated items in  place.

Liquid silicone molding (LSM): Liquid silicone molding is a process that combines two liquid polymers to create an intricate, flexible product. The chemicals are fed into the heated molds. As a result, they cure and become water-resistant for either over-molding or inserting processes with high chemical and high temperatures resistance.

Components Made Through Plastic Molding

The plastic molding process has many advantages, including creating complex shapes and sizes. This is why the production of electronics is often used to make components like cable assemblies or harnesses.

As several vital components are necessary for holding multiple wires together in cable assembly components, they include:

Fasteners and grommets: Many types and sizes of fasteners are needed to ensure the integrity of a complex wire configuration. Plastic molding efficiently produces high-yield fasteners of many sizes.

Connectors, dongles, and adapters: These products are vital for computers for their various connections and assemblies.

Strain reliefs: When you need to ensure your cables can withstand heavy pulling and stretching, plastic molding is the perfect solution for providing strain relief that protects against damage at their connection point.

Connector House Units

Connector houses are a necessary component of most electronic devices. Also known as blocks, shells, or bodies, connectors come in various shapes and sizes depending on their application, and are used to hold the assembly together. This makes plastic molding a perfect choice for fabricating complicated connector shapes.

Cable Harness Assemblies

Harnesses are made up of individual cables that come together in a single contact. First, the protective sheath will cover each cable with insulation, providing enough flexibility needed for its purpose. Then, screws or pins are added using insert molding techniques before being assembled into the desired product. Whether you need to color-code your wiring diagrams or insert metal components into connector houses, plastic molding may be the option for you.

Applications of Plastic Molding

Plastic molding for cable assemblies has been a common trend in the last few years. If you are looking to connect electronic components or machinery, this process is right up your alley. Additional common plastic molding applications are medical cable assemblies, coax cable assemblies, cable harness assemblies, telecommunications interconnects, box build assemblies, robotics devices, industrial equipment, medical-grade components, and more.


If you search for high-quality plastic molding that can handle any application from electronic interconnects and electromechanical assemblies, look no further than Emergent Industrials. We invite you to explore our database or utilize our included search engine and filters to rapidly narrow down required products with ease. Contact us today and see how Emergent Industrials can offer you the best procurement services in the market!


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