XACT EMS manufactures high-performance overmolded cables for defense, aerospace, industrial machinery, robotics, and harsh-weather field systems. Our low-pressure molding, high-pressure injection molding, and pour-molding capabilities produce assemblies that outperform traditional strain-relief and sealing methods — delivering maximum durability where failure is not an option.
Whether you require injection molded cable assemblies for maximum durability or low pressure molded protection for sensitive electronics, XACT designs each build for long-term performance.
We support multiple molding processes to match application requirements and component sensitivity.
| Process | Best For | Key Benefit |
|---|---|---|
| Low Pressure Molding (LPM) | PCB assemblies, delicate electronics | Minimal stress on components |
| High Pressure Injection Molding | Rugged connectors & strain relief | Maximum durability |
| Pour Mold | Complex shapes & low-volume builds | Flexible tooling |
| Potting & Encapsulation | Full cavity protection | Vibration & moisture resistance |
Our overmolding expertise is backed by in-house tooling, engineered material selection, and controlled process validation — positioning XACT as a full-service overmolding manufacturer, not just an assembly provider.
We design molded cable assemblies across multiple electrical and mechanical categories.
Cable & Signal Categories
| Category | Supported Applications |
|---|---|
| RF / Coax | Controlled impedance & high-frequency systems |
| Power | High-current distribution |
| Signal | Multi-conductor control systems |
| Communication | Ethernet, MODBUS, PROFIBUS, CANBUS / J1939 |
| Hybrid | Power + signal + data integration |
Assembly Configurations
| Configuration | Options |
|---|---|
| Termination Style | 2-ended, single-ended |
| Branching | Breakouts & splitters (see Molded Breakout Solutions) |
| Construction | Multi-conductor, paired/twisted, jacketed cable |
| Shielding | Shielded, non-shielded, braid shield, foil shield |
| Integration | PCB assemblies, electro-mechanical builds |
| Custom Builds | Build-A-Cable, custom extruded cable |
Low-pressure molded cable assemblies protect sensitive electronics and PCB-integrated assemblies without damaging components. Ideal for sensor assemblies, high-density signal cables, and EMI-sensitive builds.
Injection molded cable assemblies deliver structural reinforcement and repeatable production quality for rugged industrial, transportation, and defense applications.
Pour-molded and potted cable assemblies provide complete encapsulation for extreme moisture, vibration, chemical exposure, and immersion-rated environments.
Application-specific tooling engineered to optimize strain relief geometry, reduce stress concentration, and increase cable durability.
High-flex cable assemblies, RF cable assemblies, hybrid power/signal builds, and shielded cable assemblies designed for demanding field use.
Extreme-duty overmolds built for mud, dust, abrasion, oils, heat, vibration, and long-term field exposure.
Sealed overmolded interconnects for radios, soldier systems, antennas, sensors, rugged electronics, and battlefield equipment.
Overmolded connectors for repetitive bend cycles, coolant exposure, motion systems, robotics joints, and automation cells.
XACT provides full-service cable refurbishment, recertification, potting, inspection, and continuity testing.
Lightweight, vibration-resistant overmolded assemblies for avionics modules, UAV payloads, mission systems, and flight electronics.
First articles, tooling development, drawings, DFM support, and engineering collaboration.
XACT provides full-service cable refurbishment, recertification, potting, inspection, and continuity testing.
Enhance your electronics with engineered EMI and thermal materials from Matrix Technology Ltd., a trusted partner to XACT Engineered Manufacturing Solutions.
Submit your drawings, environmental requirements, or sample assemblies for evaluation. XACT provides rapid DFM support, tooling, and prototype-to-production overmolding.
Low-pressure molding, high-pressure injection molding, and pour molding.
TPU, TPE, nylon, engineered blends, and potting compounds.
IP67/68 sealing with custom sealing geometries available.
Yes — including circulars, RF connectors, tactical audio connectors, and custom backshells.
Yes — XACT supports prototypes, first articles, tooling development, and scalable production.
Overmolding is a manufacturing process where a protective polymer layer is molded directly over cable terminations or connectors to provide strain relief, environmental sealing, EMI protection, and mechanical durability.
Low pressure molding is ideal for delicate electronics and PCB assemblies, while high pressure injection molding provides maximum durability for rugged connectors and high-strain applications.
Molded breakouts provide sealed branch routing and strain relief in multi-leg cable systems. Learn more at Molded Breakout Solutions.
Yes. We support IP-rated sealing, IPC build classes, J-STD requirements, and application-specific validation protocols.
Yes. We support RF and controlled impedance systems including VSWR validation and shielding strategies when required.
1. Standard Overmolded Cable Assemblies:
2. Custom Overmolded Cable Assemblies:
3. Ruggedized Overmolded Cable Assemblies:
4. Shielded Overmolded Cable Assemblies:
5. Smart Overmolded Cable Assemblies:
6. High-Flex Overmolded Cable Assemblies:
7. Specialty Overmolded Cable Assemblies:
1. Cable Selection: Engineers should choose the appropriate cable type, considering factors such as conductor material, gauge, insulation, and shielding to meet the electrical and mechanical requirements of the application.
2. Overmolding Material: Selecting the right overmolding material, such as thermoplastic or thermoset, is crucial. It should match the cable’s material compatibility, provide adequate protection, and meet environmental requirements.
3. Mold Design: The mold design must accommodate the cable’s size and shape while ensuring proper strain relief, stress distribution, and a secure fit. Mold geometry should prevent air entrapment during the molding process.
4. Strain Relief and Flexibility: Incorporating strain relief features within the overmold design is essential to prevent cable damage at the junction between the cable and overmold. Ensure that the design allows for cable flexibility as needed for the application.
5. Environmental Considerations: Assess the environmental conditions the assembly will be exposed to, such as temperature extremes, moisture, chemicals, and UV radiation. Select materials that can withstand these conditions.
6. Connector Compatibility: Ensure that the overmolded assembly is compatible with the connectors it needs to interface with. Proper alignment and secure attachment are critical for electrical connectivity.
7. Electromagnetic Compatibility (EMC): In applications sensitive to electromagnetic interference (EMI), incorporate shielding within the overmold design to minimize EMI effects and maintain signal integrity.
8. Cable Stranding and Flex Life: Consider the cable stranding type (e.g., solid, stranded, or fine-stranded) and its impact on flexibility and fatigue resistance. Choose stranding that suits the application’s flex life requirements.
9. Testing and Quality Control: Implement thorough testing protocols, including continuity, insulation resistance, and high-potential testing, to ensure the assembly meets performance and safety standards.
10. Customization: If the application demands custom features, such as integrated sensors or connectors, engineer the overmold to accommodate these components seamlessly.
11. Cost Optimization: Balance performance requirements with cost constraints by optimizing material selection and manufacturing processes while maintaining reliability.
12. Assembly Process: Consider the assembly process, including molding techniques (compression, injection, or transfer molding), curing times, and quality control procedures to ensure consistency and reliability.
13. Serviceability and Repairability: Design with future maintenance and repair in mind, making it easier to replace components or perform repairs without extensive disassembly.
1. Automotive Wiring Harnesses:
2. Industrial Automation and Robotics:
3. Aerospace and Aviation:
4. Medical Devices:
5. Renewable Energy Systems:
6. IoT and Smart Devices:
7. Oil and Gas Exploration:
8. Military and Defense:
9. Telecommunications:
10. Consumer Electronics:
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