Customized Bulk Cable

We use the latest manufacturing processes with hands-on expertise and craftsmanship. We offer planetary cabling machines, automated lay-up tables, hand breakouts, metallic shielding / fiber braiding and jacketing to meet any need you may have.

Termination

Our team provides many termination manufacturing services, including soldering and crimping on almost every type of connector, as well as ESD assembly and custom marking/stamping.

Assembly Services

From harnesses to PCBA sub-assemblies and box builds, our Nortech teams can assemble components into testable, consolidated parts.

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 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

At 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.

Materials