Overmolding

OVERMOLDED, POTTED WIRE HARNESS AND CABLE ASSEMBLY COMPONENTS

ATRON Group is a recognized leader in the overmolding of thermoplastic elastomers (TPEs) and potting of thermoset polymers (TSPs).

ATRON has developed several innovative technologies that have continued to set the standard in overmolding. Our overmolding and potting product line include a variety of TPE technologies designed to deliver optimum adhesion to many engineering plastics in both insert and two-shot molding processes.

When working with ATRON, you get the benefit of a world-class application development team spanning:

• Component design knowledge.
• Valuable tooling input.
• Creativity in molding process knowledge and material combinations.

DESIGN CONSIDERATIONS FOR OVERMOLDED/POTTED ASSEMBLIES

Overmolding/potting can be used to enhance many features of product designs, protection against the elements, abrasion resistance, and EMI (electromagnetic Interference) performance. Sealing of the components offering water-resistant and watertight encapsulation. Other benefits include:

• Encapsulation: Sealing of critical components providing specified levels of ingress protection (for example IP67)
• Strain Relief: For added flexibility is important to the electrical and mechanical integrity and overall performance of an assembly. A strain relief is used to provide a transition from the rigid connector or connection point to flexible cable preventing violation of bend radius standards
• Gripping: features that provide for non-slipfinger grips can be designed into the overmold for ease of use
• Security: Positive or passive latching features which lock connectors in place and prohibits disconnection during use
• Branch Routing: Uniquely designed trunk and branch molding for exacting routing and layouts

OVERMOLD AND POTTING TOOLING

ATRON designs its tools based on a modular quick-change concept. The components that makeup tooling for high-pressure overmolding include:

• Mold Cavity: The part of the tool which will produce the body of the molded component
• Loading Bars: Securely holds the connector housings, pins, or other components in the proper position within the tool during the overmolding process
• Locating pins: Securely holds wire or “floating” components in the proper position within the tool during the overmoldingprocess
• Strain Relief: The portion of the tool which molds a solid or segmented bend relief joining and potentially sealing between the connector to the cable jacket material
• Gripper Bars: Holds the cable in the proper position during overmolding acting as either a guide for the strain relief or a “shut-off for the flow of resin.

COLLABORATION AND LEAD TIMES

ATRON follows an exacting process for discovery and critical customer communications. The customers design inputs are essential to design outcomes that meet expectations for quality and on-time completion. Regular collaboration between ATRON and the customer is critically important while developing the final molded configuration. Tooling fabrication is typically the longest lead item of a project, ranging from 8 – 14 weeks.

ABOUT ATRON GROUP

ATRON Group LLC, an AS9100 registered company based in Dallas, Texas with over 25 years of excellence in the Contract Manufacturing Services space. ATRON, a custom electro-mechanical and fabricated component contract manufacturer, “Manufacturing services company,” provides Custom Equipment Integration, Control Systems, Electro-Mechanical Assembly & Precision Sheetmetal Fabrication Services to a broad range of Industries. 

“The most important thing we build is Trust”

 ATRON Group LLC

Bop Potysman, President/CEO

At ATRON Group we are “Quality-Fanatics”. We understand that everyone experiences issues from time to time, but at ATRON we know it’s how we take care of those issues that sets us apart from other MSPs. We understand the most important thing we build is trust. We are more than our AS9100 and ISO9001 registrations, more than our UL Recognitions and accreditations, more than our commitment to standards like IPC/WHAM-A-620. We are the fastest growing MSP in our space.

To learn more about custom electro-mechanical assemblies and our Manufacturing Services from ATRON, contact us at our manufacturing center in Dallas, Texas (USA) or call us at 214-292-9840.