Molded Cable Assemblies

For rugged applications, you need the reliability and sensibility of a molded cable design. Molded connector strain reliefs and junctions provide superior dependability.  These assemblies are sealed for life and provide superior environmental and abrasion protection, shock and impact resistance, and a customizable fits for tight quarters or unique angle connectors.  Molded cables do not pull out or break apart when in contact with the cold or with age, so replacement needs and costs will go down.

 

How They’re Made

Molded Cable AssembliesMolded cable assemblies can be created with a few different methodologies, each provide their own benefits. Using a casted two-part process provides excellent sealing properties as the materials used chemically bond to the backshells and cable jackets. These materials are chemically cured materials, which won’t melt or deform with temperature.  These materials can be economically used in very low quantities and can scale up to high quantities using inexpensive tooling.

Moldings can also be created with rubber (elastomer) transfer molding. This process uses uncured rubber, which is pushed into the mold and cured with pressure, temperature and time.   Rubber molded cables are designed to be molded to similar rubber jackets (e.g. EPDM to EPDM), which may provide extra dependability.

Lastly, there’s the option of injection molded cables using thermoplastics, which can provide superior aesthetics, including detailing and surface texturing. Using primers, thermoplastics can be bonded to other thermoplastics and metals.  Injection molding is ideal to high volume production run rates.

 

Choosing the Right Tooling

Molded Cable Assembly ConnectorsAt Nortech, we offer two methods to tool for molded cable assemblies. For most cases, we use traditional metallic-based tools, which would be aluminum for most cases and steel for high volume designs.  These tools are simple to design and inexpensive to manufacture.  Additionally, a number of popular, circular connector designs may already have tools in place.

For some applications, injection mold tooling may be more appropriate, including many D-Sub and circular connectors. In this variant, aluminum tooling or steel tooling with special inserts can be acquired for moderate cost, but for sub-100 production runs, a 3-D printed mold tool can provide reasonable cost and quick turn prototype and production capabilities.  At Nortech, we provide a 3-D printer on-site specifically to support quick-turn mold designs.

 

A History of Success and Support

At Nortech, we’ve established a decades-long record of producing quality molded cable assemblies and supporting some of the world’s most demanding aerospace and defense applications. You’ll find our products within premier DoD programs, including:

Abrams Tank M1/A1
ACMI – Air Combat Training POD
ACMI Pod Umbilical
ACMI Pods Internal
Advanced Hawk Eye (AHE)
AEGIS Shipboard
AH-64 – Apache Longbow
AIM 120 AMRAAM
AIM-9L Sidewinder Missile
Aircraft Interface Simulator (AIS)
AMMPS (Power Generators)
Arrow Interceptor Missile
ATFLIR (AN/ASQ-228) Targeting POD
AVCATT Trainer (Helmet)
AWES-MOD Training Simulation
B1B – Lancer Bomber
B-52 – Stratofortress Bomber
BFVS – Bradley Fighting Vehicle Systems
Boeing 777
Boeing 787
BQM-74 – Target Drone
BRU-32 – Bomb Ejector Rack
C-130 Hercules
C-17 Globemaster
Command Voice
Crusader Howitzer
DSIU-Radio System
Electric Brake (Aircraft)
EMUT Radio System (AN/PSC-5)
ESSM-SeaSparrow Missile
F-14 – Tomcat (Aircraft)
F-15 Strike Eagle (Aircraft)
F-18 – Super Hornet
F-22 Raptor
F-35 JSF Lightning II
F-4 Helmet Gunsight System
F404 Engine
F-5 (Aircraft)
Falcon II Radio System (AM/PRC-150)
Fire Scout UAV (MQ-8)
Global Hawk UAV (RQ-4)
GRC-206 Radio System
Harpoon GSE
Have Quick II Radio System (AN/ARC-164)
Heated Hose Assembly (Dispensing or Robotic)
IHADDS – Helmet Assembly
ITS – Independent Target System
IWS – Individual Weapon System
JASSM Missile
JATO-Jettison Release Mechanism
JLTV Vehicle
JTRS Radio System
Land Warrior – Weapon System
LOSAT (MGM-166)
LRAS3 (Surveillance)
M1114 – (Up-Armored HMMWV)
M-ATV (MRAP All-Terrain Vehicle)
Maverick Missile (AGM-65)
MBMMR (AN/PSC-5D)
MEADS Defense System
MILES 2000 – Training Simulation
MK 105 Mine Detector Sled
MK 46 Torpedo
MK13-MK14 VLS Launcher
MK-41 (Vertical Launch Systems)
MK86 Gun Fire Control System
MK92 Guided Missile Fire Control System
MK95 Fire Control Radar
MK-VII – Laser rangefinder
Mounted Warrior (Helmet and body worn)
MRAP – Mine Resistant Ambush Protected Vehicles
MTS – Movement Tracking Systems
MTS-B (Targeting System)
MULE – Autonomous Vehicle
Patriot Missile (MIM-104)
Paveway (GBU-12) Laser-Guided Bomb
Peacekeeper Missile (LGM-118)
Predator UAV (MQ-1)
Quick Strike Missile
Regency Net Radio System (GRC-215)
Regional Jet
Robotic Shell Loader
SDB II (GBU-53/B) Small Diameter Bomb
Seawolf (SSN) Submarine
Shadowfire – Radio System (AN/PSC-5V)
Shrike Missile Umbilical (AGM-45)
SINCGARS Radio Systems
Small ICBM Missile (MGM-134)
Smart Bomb
Sparc 20 – Mainframe Computer
Spitfire – Radio System (AN/PSC-5)
Striker Vehicle
Titan IV (Payload Rocket)
Tomahawk Missile
TOW II Anti-Tank Missile (BGM-71)
Trident II (SSBN) Submarine
UH-60 – Blackhawk
VIS – Vehicle Intercom System (VIC-3, VIC-5)

Materials

  • Polyurethane (MIL-M-24041 Cat. B Type 1)
  • Neoprene (MIL-PRF-6855 Class 2, Type A, Grade 60)
  • Ethylene Propylene Diene Monomer [EPDM] (ASTM D 2000 M2DA607)
  • Viton® / Fluorocarbon Elastomer (ASTM D 2000 M3HK607A1-10B37C12EF31 or AMS 3216)
  • Thermoplastic Polyurethane (Lubrizol Estane® 58300, 58202 and 58370)
  • Silicon Grades
  • Epoxies
  • Thermoplastics

Certifications

  • ISO 9001:2008 Certified
  • AS9100 Certified
  • ITAR Compliant
  • MIL-I-45208 Compliant
  • J-STD-001 Compliant

 

Contact us today for your next custom molded cable assembly project

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