Overmolded cable assemblies built for the places cables fail.
Mithril Industries designs the mold, machines the tooling and overmolds your assembly in-house — sealed, strain-relieved and tested so it survives water, shock, chemicals and constant flexing.
- ~1 weektypical in-house mold turnaround
- 100%electrical test on every assembly
- HP + LPhigh- and low-pressure molding
- Class 3IPC/WHMA-A-620 workmanship
One molded body instead of tape, glue and hope.
Overmolding fuses the connector, cable and strain relief into a single sealed part. The weak point where cables usually fail — the back of the connector — becomes the strongest part of the assembly.
Sealed against the elements
IP68-rated designs keep out water, mud, dust and salt spray — above ground, underground or offshore.
Strain relief & flex life
Tapered, molded boots spread bending loads so assemblies survive tension and continuous flexing without cracking.
Shock, vibration & impact
A solid molded body resists crushing, shearing, abrasion and direct impact in vehicles, rigs and field equipment.
Oil & chemical resistant
Material options rated for petrochemicals, fuels, hydraulic fluids and cleaning agents.
Extreme temperatures
Compounds selected for operation from −40°C to +85°C, including cold-weather flexibility and UV exposure.
Branded & identified
Logos, part numbers and keying features machined directly into the tool, so every part is marked permanently.
We machine our own molds. That changes the schedule.
Most overmolding programs stall waiting on an outside toolmaker. Mithril designs and CNC-machines precision molds under the same roof as molding and assembly, so a new tool typically takes about a week — at a fraction of the cost of outsourced tooling.
- Mold design from your connector, cable and envelope constraints
- CNC-machined aluminum and steel tooling
- Reusable tool library for fast repeat orders and variants
- Prototype-to-production with the same tool
Maximum durability
Thermoplastic polyurethane, TPE and TPR injection-molded at high pressure for the toughest jackets and boots.
- Abrasion & impact resistance
- Continuous-flex robotics cables
- Military & heavy-industry connectors
Protects what’s inside
Polyamide hot-melt molding at low pressure and temperature to encapsulate delicate components without damage.
- PCB & sensor encapsulation
- Fine-pitch solder joints
- Fast cycle, minimal tooling stress
From sketch to sealed assembly
- 01
Consult
We work directly with your engineers on environment, loads, connector and cable selection.
- 02
Design & tool
Mold geometry, strain relief and branding are designed and machined in-house.
- 03
Mold & build
Assemblies are terminated and overmolded with high- or low-pressure processes.
- 04
Test & ship
Every assembly is electrically tested and inspected before it leaves the building.
Matched to your environment — and your brand
Jacket and mold compounds are chosen for the job, and a range of in-stock colors makes coding, identification and branding simple.
Where our overmolded assemblies go to work
Defense & aerospace
Military and light-armored vehicles, radar, counter-UAS, wearable soldier systems, breaching and field medical equipment.
Oil, gas & energy
Land and offshore drilling, production platforms, pump jacks, logging and measurement-while-drilling (MWD) tools.
Robotics & automation
High-cycle, high-torsion continuous-flex cables for robot arms, cable tracks and automated equipment.
Industrial & mining
Heavy equipment, remote monitoring, data acquisition and power, control and signal runs in abrasive sites.
Security & communications
Surveillance, tactical communications and remote sensing deployed outdoors year-round.
Agriculture & transportation
Harnesses exposed to mud, washdown, fertilizers, fuel and constant vibration.
Tested one by one — not by the batch
Overmolding makes an assembly permanent, so we verify everything before and after the mold closes. No sample-based shortcuts.
- 100% electrical testing continuity, shorts and hipot as specified
- Visual & dimensional inspection against drawing on every part
- Pull & mechanical testing to validate strain relief and retention
- Full material traceability from connector and cable lot to shipment
- IPC/WHMA-A-620 Class 3 workmanship for high-reliability builds
Common questions
What overmolding processes do you offer?
Both high-pressure injection molding (polyurethane, TPE, TPR) and low-pressure hot-melt molding (polyamide), so we can match the process to the durability and component-protection your design needs.
When should I choose low pressure over high pressure?
High pressure gives the toughest, most abrasion-resistant result. Low pressure is gentler and is the better choice when the mold encapsulates sensitive electronics, sensors or fine solder joints.
Why does in-house tooling matter?
Because the mold is usually the longest lead-time item. Designing and machining it ourselves shortens schedules to around a week and keeps tooling costs low, which also makes design changes affordable.
Can you handle high-vibration and continuous-flex applications?
Yes. Strain-relief geometry, cable selection and compound hardness are engineered for the vibration, torsion and flex cycles of your application.
Do you work from our connector and cable, or supply them?
Either. We can source connectors and cable to your specification, or mold onto components you supply.
Tell us about your project.
Send a drawing, a photo of a failed cable or just a description of the environment. We’ll come back with a molding approach and a quote.