Low Pressure Overmolding Services for Cable Assemblies and Electronic Components
At CSE Solutions, we specialise in low-pressure overmolding — a proven process that strengthens and protects cable assemblies and electronic components. By encapsulating cables, connectors, and circuitry in advanced overmolding materials, we provide robust protection against:
- Dust and environmental contaminants
- Moisture and water ingress
- Vibration and impact
- Mechanical strain and stress
From rapid prototyping to high-volume production, our expertise ensures reliable, long-lasting solutions for medical, defence, industrial, and other demanding applications.
Our Services
Overmolded Weatherproof Cables
Sealed against water, dust, and corrosion, our overmolded weatherproof cables deliver reliable performance in outdoor, industrial, and mission-critical environments. They are widely used in defence and aerospace systems, medical equipment, industrial automation, transportation, renewable energy, and telecommunications—maintaining signal integrity and mechanical strength even under the harshest conditions.
Overmolded Cable Splitters
Engineered for secure data and power distribution, our overmolded cable splitters create durable, insulated junctions that resist signal loss, wear, and environmental damage. They are widely used in defence and aerospace systems for rugged field connections, in medical equipment where reliability and sterility are critical, in transportation networks where safety and long-term durability are paramount, in environmental monitoring systems that must withstand harsh outdoor conditions, and in industrial automation where uninterrupted performance is essential.
USB Molds
Our overmolded USB housings provide robust, impact-resistant protection against wear and mechanical stress. Used in consumer electronics, industrial equipment, and high-performance applications, they deliver custom-fitted, transparent or opaque solutions that enhance reliability and extend product lifespan and allow functional LEDs to be visible.
Customer Success Stories
Overmolded Cable Assemblies for Defence
The Challenge: Assemblies needed to withstand vibration, dust, moisture, and extreme temperatures.
Our Solution: Overmolding with high-performance thermoplastic provided robust sealing and strain relief without damaging sensitive electronics.
The Result: Improved reliability, extended equipment life, and reduced maintenance costs.
Customer Feedback: “The locally made and overmolded cable assemblies from CSE Solutions gave us flexibility for design changes, small batch runs to suit customer requirements. Greater control over our product rather than dealing with issues in an offshore location.”
Low Pressure Overmolding facilities, equipment and processes
Our Facilities
Our purpose-built facilities combine advanced surface preparation and precision-controlled molding equipment to ensure consistently high performance.
Contact Glenn our CEO or Annette our Production Manager on 9482 1944 for a personalised guided tour of our Low-pressure overmolding facilities and Electrical Testing station.
Operating under ISO 9001:2015 quality management standards, we ensure consistent processes, full traceability, and the use of genuine parts while combining modern equipment with proven techniques to deliver overmolded products that meet the demanding requirements of medical, defence, industrial, and harsh-environment applications.
Plasma Wand Surface Preparation
We use the Plasma Etch Plasma Wand as part of our overmolding process improving adhesion and reliability by cleaning and activating cable and connector surfaces.
Benefits across industries:
- Medical – enhances seal integrity for sterilisation-ready devices.
- Defence – improves durability and environmental resistance for rugged navigation and communication equipment.
- Industrial & Harsh Environments – increases bond strength and reliability in equipment exposed to dust, moisture, and vibration.
Overmolding Equipment Setup and Process
Step-by-Step Process
- Design & Build the Tool – create a mold tailored to the cable assembly or component.
- Prepare Components – clean and position parts for accurate encapsulation.
- Set Up Low-Pressure Machine – load and heat polyamide material.
- Injection – introduce molten polyamide at low pressure, flowing gently around sensitive electronics.
- Cooling – material solidifies quickly, locking components into place.
- Release & Inspect – remove the finished part, trim if needed, and verify quality.
Equipment Options
Low-Pressure Molding Machines – used for standard production, injecting molten polyamide at controlled low pressure (20–500 psi) to ensure full encapsulation without damaging electronics.
Handheld Overmolding Gun – ideal for small tools, prototypes, or low-volume runs, offering flexibility and cost- effectiveness without large-scale machinery.
Our adherence to ISO 9001:2015 ensures that every step—from tool design to final inspection—meets stringent quality standards, giving our medical and defence clients confidence in the reliability, safety, and compliance of every product.
Common Materials for Low Pressure Overmolding (LPM)
| Material Type | Typical Trade Names | Key Properties | Advantages in LPM | Common Applications |
|---|---|---|---|---|
| Polyamide (PA) – e.g., Nylon, PA6, PA12 | Henkel Macromelt (popular LPM resin) | Good chemical resistance, tough, semi-crystalline thermoplastic, recyclable | Strong adhesion to substrates, good temperature resistance, fast processing | Automotive connectors, sensors, PCB encapsulation |
| Thermoplastic Elastomers (TPEs) | Santoprene, Versaflex | Flexible, rubber-like feel, good impact resistance | Provides strain relief, ergonomic finishes, soft-touch surfaces | Cable overmolding, grips, strain relief boots |
| Polyurethane (PU) | Tecoflex, Pellethane | High abrasion resistance, excellent flexibility, good wear | Absorbs vibration, durable in harsh environments, seals well | Medical devices, flexible electronics, wearables |
| Polyolefins (PP, PE blends) | Various commodity grades | Lightweight, good chemical resistance, recyclable | Low cost, moisture resistance, flexible processing | Consumer electronics, simple encapsulations |
| Hot-Melt Polyamides (Specialty blends) | Henkel Macromelt OM series | Low viscosity, fast curing, eco-friendly | Specifically engineered for low pressure processes, minimal thermal stress | PCB protection, LED encapsulation, automotive electronics |
Testing & Standards
CSE Solutions places strong emphasis on validation to ensure every overmolded assembly delivers reliable, long-term performance.
- Ingress Protection (IP) Ratings – Assemblies can be designed and tested to meet standards such as IP67 (protection against dust and temporary water immersion) and IP68 (protection against continuous immersion), making them suitable for demanding environments.
- Design Validation – Advanced Moldflow analysis and simulation tools are used during development to predict material flow, adhesion, and stress points. This reduces risk, optimises designs, and ensures robust results before tooling.
- Performance Testing – Assemblies may undergo environmental, electrical, and mechanical testing to verify compliance with the requirements of defence, medical, industrial, and transportation applications.
- Certified Quality Processes – All testing and validation is supported by our ISO 9001:2015 certified quality management system, along with industry-specific certifications, ensuring consistent processes, full traceability, and compliance with customer and regulatory requirements.
By combining simulation-driven design, standards-based testing, and certified processes, we provide customers with confidence that each solution will perform reliably in critical applications.
Why Low Pressure Overmolding
Low pressure overmolding (LPM) is a manufacturing process where a soft or flexible material (often silicone, polyurethane, or thermoplastic elastomer) is molded over a pre-existing part (usually a rigid component or assembly) using low injection pressure. This is different from conventional high-pressure injection molding, which can damage delicate components or electronics.
Key Benefits
- Protects Sensitive Electronics – prevents stress or deformation of delicate components such as PCBs, connectors, sensors, and fine wires.
- Environmental Resistance – shields against dust, moisture, vibration, and shock.
- Extends Product Life – reduces component wear, scrap, and rework.
- Supports Complex Designs – allows overmolding of assemblies that cannot withstand high-pressure flows, enabling custom geometries and multi-material parts.
- Improves Adhesion & Durability – materials bond effectively at low pressure, creating long-lasting, high-performance assemblies.
- Lightweight & Ergonomic Finishes – delivers smooth surfaces, soft-touch grips, and compact designs.
- Cost-Effective for Sensitive Parts – fewer damaged parts and less material waste reduce overall production costs.
Industries That Benefit from Overmoulding
- Military & Defence – Provides rugged, weatherproof cable assemblies for harsh environments, battlefield communication, and mission-critical systems.
- Medical & Healthcare – Protects cables in diagnostic devices, patient monitors, and surgical equipment, ensuring biocompatibility.
- Aerospace & Aviation – Lightweight, durable overmoulded wiring systems withstand extreme temperatures, high-altitude pressure, and vibration.
- Security & Surveillance Systems – Protects CCTV, alarm system cables, and biometric devices, preventing tampering and environmental damage.
- Industrial & Automation – wear-resistant solutions for robotics and machinery.
- Telecommunications & Networking – reliable connectors and cables for RF, fibre, and broadband.
- Automotive & Transport – Used in wiring looms, sensor cables, and power distribution, improving heat resistance, vibration damping, and durability.
- Environmental Monitoring & Agriculture – Used in sensor cables, irrigation control, and outdoor monitoring devices, ensuring moisture and corrosion resistance.
- Consumer Electronics & USB Technology – Strengthens USB cables, charging ports, and audio connectors, preventing bending damage and wear.
- Renewable Energy & Power Distribution – Improves power connectors and solar panel cables, ensuring safe, high-performance energy transfer.
Certification & Compliance
- ISO 9001:2015 Certified Quality Management System
- IPC/WHMA-A-620E Certified Application Specialists
- JOSCAR-AU registered
- NCAGE CODE: Z31J59
Contact Us to Start Your Overmolding Project
Protect your components with precision low pressure overmolding. From rugged defence cables to medical-grade and industrial-strength solutions, CSE Solutions has the expertise to deliver. Call Glenn our CEO on 02 9482 1946 or Annette our Production Manager on (02) 9482 1394 to discuss your project today or arrange a tour of our facilities.
FAQs
What is low-pressure overmolding?
Low-pressure overmolding is a manufacturing process that applies a protective layer of overmold material over cables, connectors, or electronic components. This overmolding process enhances durability, resistance to moisture, dust, vibration, and mechanical stress, while maintaining the precise tolerances needed to ensure reliable, fit, function and repeatability in critical applications
2. What are the benefits of low-pressure overmolding?
Low-pressure overmolding protects delicate electronics and circuit boards by using lower temperatures and significantly reduced pressures compared to traditional injection molding. This gentle process prevents component damage while improving durability, sealing, and strain relief. It also delivers high precision with shorter cycle times, giving manufacturers strong, dependable parts at lower cost—a practical choice across industries from consumer electronics to medical and defence.The low-pressure moulding process protects delicate electronics and circuit boards by using lower temperatures and pressures. It improves durability, prevents component damage, and provides reliable sealing with strain relief. Compared to traditional injection moulding, this overmoulding process delivers high precision with shorter cycle times. Manufacturers gain strong and dependable finished parts with lower costs, making it a practical choice across several industries.
3. What materials are used in low-pressure overmolding?
Common materials include thermoplastic elastomers (TPEs), and polyurethane. These are chosen based on material selection factors like flexibility, chemical resistance, and durability. The right overmould material depends on the final product, with each option offering many unique benefits for performance in several industries.
4. How is low-pressure overmolding different from high-pressure overmolding?
Low-pressure overmolding uses lower injection pressures, which reduces the risk of damaging delicate components and ensures precise control for sensitive assemblies. The process allows accurate control when forming the desired shape of the molded part. Compared to high-pressure injection molding, it has shorter cycle times and lower costs. This makes the low pressure molding process a better option for applications that need high precision and reliable overmolded parts in several industries.
5. What equipment is used in low-pressure overmolding?
Low-pressure overmolding uses specialized molding machines that operate at lower pressures to protect sensitive components. For small runs or prototypes, handheld overmold guns and insert tools are common. These machines heat and inject thermoplastic materials around cables, connectors, or circuit boards, creating a protective, sealed finish without damaging the underlying parts.
6. How is low-pressure overmolding used in the medical industry?
Low-pressure overmolding is used in the medical industry to protect devices such as catheters, sensor cables, and diagnostic tools from moisture, cleaning agents, and mechanical wear. With the right choice of biocompatible materials, the process creates a sealed, durable layer around sensitive components while supporting the strict design and regulatory requirements of medical applications.
7. Why is low-pressure overmolding important in defence applications?
Low-pressure overmolding is important in defence applications because equipment must perform reliably in harsh environments. The process creates overmolded parts that resist vibration, extreme temperatures, and environmental stress. By sealing and protecting sensitive electronics, connectors, and communication cables, low-pressure overmolding enhances durability and ensures dependable operation in the field.
8. Can low-pressure overmolding be used for industrial applications?
Yes. Low pressure overmolding is widely applied in industrial automation and manufacturing. It is used for automotive parts such as wiring harnesses and sensors, robotics cables, and power assemblies in harsh factory conditions. The injection molding process protects each moulded part with sealing and strain relief.
9. Are low-pressure overmolded components customisable for specific industries?
Yes. Overmolding offers flexibility for design considerations across several industries. Components can be customised with colour coding for identification, adjusted material hardness, or a specific plastic housing that suits the application. Different surface treatments improve sealing and visual appeal, while material selection balances strength and flexibility.
10. Can low-pressure overmolding help with electrical insulation?
Yes. Overmolded materials provide electrical insulation and strain relief, protecting sensitive circuits from shorts, moisture, or vibration damage.
11. How do you ensure quality and compliance in critical industries like medical and defence?
We ensure quality and compliance in critical industries like medical and defence by adhering to ISO 9001:2015 certified processes. This includes:
- Using industry-approved, verified, and genuine materials.
- Following stringent testing protocols for environmental, electrical, and mechanical performance.
- Maintaining full traceability and comprehensive documentation to meet regulatory requirements and support audits.
Our ISO-certified systems give clients confidence that every component and assembly meets the highest standards of safety, reliability, and compliance.
12. Why choose CSE Solutions for Low Pressure Overmolding?
CSE Solutions specialises in the low-pressure molding process, delivering high-quality, durable cable assemblies and electronic components. Our ISO 9001:2015 certified processes ensure every part is made with industry-approved, non-counterfeit materials and full traceability, meeting the strict requirements of medical, defence, industrial, and other demanding sectors. From rapid prototyping to high-volume production, we provide custom solutions that enhance durability, reliability, and compliance in every application.
13. What IP ratings can be achieved with low pressure overmolding?
Low pressure overmolding can achieve ingress protection ratings such as IP67 (dust-tight and resistant to temporary water immersion) and IP68 (dust-tight and resistant to long-term immersion). The exact rating depends on the design, material selection, and testing requirements of the application. With proper design and validation, overmolded assemblies can reliably withstand harsh environmental conditions in defence, medical, industrial, and outdoor applications.
14.How does low pressure overmolding compare to potting in terms of cost and sustainability?
Low pressure overmolding is generally more cost-effective than potting because it uses less material, has shorter cycle times, and eliminates the need for secondary housings or enclosures. It also provides precise, repeatable encapsulation, reducing rework and scrap. From a sustainability perspective, low pressure overmolding consumes less energy, generates less waste, and often uses recyclable thermoplastics—whereas potting typically relies on epoxies or resins that are difficult to recycle and have longer cure times.
15. What design considerations should be made before tooling for low pressure overmolding?
Key design factors should be addressed early to ensure a successful outcome:
- Part Geometry – Avoid sharp corners or deep undercuts that restrict resin flow.
- Material Selection – Match overmold material to the substrate for strong adhesion and desired performance (e.g., chemical resistance, flexibility, or heat tolerance).
- Component Placement – Ensure sensitive electronics, connectors, or cables are positioned to allow complete encapsulation without voids or stress points.
- Gating and Flow – Plan for resin entry and venting to optimise filling and reduce air entrapment.
- Testing Requirements – Consider environmental and IP rating targets up front so designs can be validated against relevant standards.
Engaging in Moldflow analysis and design simulation before tooling can further reduce risk, shorten development time, and optimise reliability.