Custom overmolding for cable assemblies.
Mithril Industries manufactures custom overmolded cable assemblies that deliver reliable and durable solutions for complex interconnect problems in challenging environments, made to withstand the forces of nature.
- Fast toolingindustry-leading tooling times for custom molds
- 100%electrical test on every assembly
- HP + LPhigh- and low-pressure molding
- Class 3IPC/WHMA-A-620 workmanship
Increase reliability with custom overmolding.
Our cables are built extremely tough to resist crushing, shearing, cold weather, salt spray, petrochemicals, mud and grime, severe shocks, abrasion, tension, vibrations, extreme heat, water exposure, sun exposure and continual flexing without breaking down.
IP68 rated
Sealed overmolds keep water, mud, grime and dust out of the connection, above ground, underground or offshore.
−40°C to +85°C
Capable of operating from −40°C to +85°C, through cold weather, extreme heat and sun exposure.
Oil & chemical resistant
Oil and chemical resistant options that are extremely tough and flexible.
Shock, vibration & impact
Our assemblies withstand shock, vibration and direct impact without damage to the termination point.
Continual flexing
Molded strain relief takes continual flexing and tension, so the termination point doesn’t fatigue or break down.
Branded & identified
Branded or identifier options using precision tooling, with an embossed or pad-printed personalization on the overmold itself.
Industry-leading tooling times for custom molds.
With custom mold tooling for each project and many manufacturing materials to choose from, we offer complete custom and cost-effective options to ensure dependable connections in the field.
- Mold tooling designed around your connectors and cable
- Industry-leading tooling times for new custom molds
- Your tooling kept on file for repeat orders
- Embossed or pad-printed branding on the overmold
Polyurethane, for maximum durability
High-pressure (polyurethane) overmolding is used for maximum durability.
- Abrasion & impact resistance
- Continuous-flex robotics cables
- Military & heavy-industry connectors
Macromelt, to protect what’s inside
Low-pressure (macromelt) overmolding is often used to protect sensitive internal components.
- PCB & sensor encapsulation
- Fine-pitch solder joints
- Gentle on delicate electronics
Collaborative custom overmolding solutions
Our collaborative approach ensures that your custom overmolded cable assemblies are exactly what you need, with quality that will stand the test of time.
- 01
Work with you
We work directly with each client on the application, the environment and the requirements.
- 02
Connectors & cable
We select the right connectors and cable for the job.
- 03
Mold tooling
Custom mold tooling is designed and built for your assembly, with industry-leading tooling times.
- 04
Solve & build
We problem-solve unique solutions to challenging applications, then mold, test and ship.
Custom overmolding color options
Mithril offers an array of in-stock color options for overmolding. In addition to color selection, we can personalize your overmolding with brand logos or identifiers specific to each project. We also offer custom colors, with minimum order quantities.
Our custom overmolding for cable assemblies
Ask us about custom work for your next project.
Custom overmolding for many sectors, including:
Defense
Mithril builds custom overmolded cable assemblies for the defense industry, including harnesses for military vehicles such as light armored vehicles, armored tactical vehicles and troop carriers.
- Rugged custom molds for vehicle harnesses, and molded “T” adapters for efficient routing
- Weight reduction and improved durability
- High torque and repetitive motion
- Shielding for signal performance and clarity
- Overmolded cables for advanced short-range radar and drone defense systems
- Overmolded cables for wearable soldier systems and K9 reconnaissance units
- Overmolded cables for breaching systems and field medic systems, including respirators and ventilators
Industrial
Our custom overmolding suits a vast array of applications, including special security projects, communication systems on oil and gas rigs, data vans, computer systems on mining trucks, remote monitoring for farms and forestry, surveillance cameras for law enforcement, electronic systems for military vehicles and naval ships, asset monitoring and tracking for the transportation industry, radar for drone defense systems, torque guns for wind turbines, solar installations, continuous flex cables for robots, wearable cables for soldier systems and K9 surveillance units, antenna cables for science and exploration, avionics and more.
Oil & gas
Rugged overmolded cable assemblies that increase durability and solve the unique problems found on land and sea rigs, with durable jacket options including polyurethane, thermoplastic elastomer, thermoplastic rubber, Teflon® and many more.
Our cables are built to withstand abrasion, extreme heat, water ingress, blunt force impact, extreme cold, continuous flex, vibration, extreme pull force, EMI, rough handling, chemicals, oil, pests and more, for land-based oilfield drilling, well sites, production platforms, offshore drilling, pump rooms, pump jacks, logging systems, data vans, measurement-while-drilling, seismic systems, data acquisition and telemetry, oilfield service and rig communications.
Robotics
Robotics cable assemblies are at risk of failure due to twisting and turning over the course of hundreds of thousands of cycles, as well as the wear that comes from operating in industrial environments.
To reduce downtime, industrial robotics cable assemblies need to withstand high torsion and harsh operating conditions. Mithril manufactures custom robotics cable assemblies with continuous flex cable and special strain relief overmolded connections that resist wear and tear, reducing downtime and saving you money.
Tested one by one — not by the batch
Overmolding makes an assembly permanent, so we verify everything before and after the mold closes. No sample-based shortcuts.
- 100% electrical testing continuity, shorts and hipot as specified
- Visual & dimensional inspection against drawing on every part
- Pull & mechanical testing to validate strain relief and retention
- Full material traceability from connector and cable lot to shipment
- IPC/WHMA-A-620 Class 3 workmanship for high-reliability builds
Frequently asked questions
What are your overmolding capabilities?
We provide both high-pressure (polyurethane) and low-pressure (macromelt) overmolding solutions, with industry-leading tooling times for custom molds.
What is the difference between high-pressure and low-pressure overmolding?
High-pressure (polyurethane) is used for maximum durability, while low-pressure (Technomelt) is often used to protect sensitive internal components.
Why do tooling times matter?
The mold is often the longest lead-time item in an overmolding project. Industry-leading tooling times for custom molds allow for rapid design and manufacturing, significantly reducing lead times for molded assemblies.
Can Mithril manufacture cables for high-vibration environments?
Yes. Our overmolded assemblies and mechanical engineering focus ensure reliability in high-vibration applications.
Ready to discuss your custom overmolding project?
Tell us about your project: the application, the environment it has to survive, and the connectors and cable if you know them.