Capability · CAP-04
Overmolding.
TPE / PVC / Silicone. IN-HOUSE TOOLING.
Single-shot and double-shot insert-injection cells, fed by our sister mold-tooling shop on the same floor. Five material families from 30 to 95 Shore-A, USP Class VI for medical, 50,000+ flex cycles validated per IEC 60068-2-31. Cycle time 25–45 seconds.
65
Shore-A Max
Single-shot TPE/PVC
50K+
Flex Cycles
IEC 60068-2-31
25-45
Cycle Sec
Per shot, AWG-dep
$800
Proto NRE
Single-cavity tool
USP Class VI
Medical Grade
Silicone + TPE-V
5
Material Families
PVC, TPE-S, TPE-V, TPU, Si
Single + Double
Shot Cells
Two-color & dual-durometer
In-House
Mold Tooling
$3-12K production NRE
What Overmold Means Here
The Tool, The Material,
The Insert.
All Under One Roof.
Overmolding turns a wire harness into a sealed assembly — strain relief, IP67 sealing, ergonomic grip, color-coded boot. XDPI runs single-shot and double-shot insert-injection cells fed by pre-terminated, Cirris-passed harnesses. Five material families: PVC (cost-down), TPE-S (sweet spot 65 Shore-A), TPE-V (USP Class VI medical), TPU (abrasion + chemical resistance), and silicone (autoclave / -55 / +200 °C).
What separates the cell from a generic injection-molding shop: the mold-tooling shop sits on the same Cavite floor. Prototype tools $800–$2K cut in 18–28 days; production multi-cavity tools $3–12K NRE amortized over 5K–10K units. ECN tool revs turn in 4–7 days because the engineer who cut the tool revises it.
Overmold cells feed overmolded harness programs and waterproof harness programs. Strain reliefs validated to 50,000+ flex cycles per IEC 60068-2-31 on the in-house Igus chainflex bend rig. Post-overmold harnesses get re-tested on Cirris benches plus an IP67/IP68 immersion check before MES sign-off.
Six Overmold Dimensions
What Holds The Boot.
Single-Shot Overmold
Standard insert injection of TPE-S, TPE-V, PVC or TPU around pre-terminated harnesses. Hardness 55–95 Shore-A typical, 65 Shore-A as the strain-relief sweet spot. Cycle 25–45 s.
OVM-01
Double-Shot Overmold
Two-color or dual-durometer molds for ergonomic grips and color-coded plug ends. Soft TPE skin (50 Shore-A) over a structural Nylon 66 core. Used heavily on medical and consumer harnesses.
OVM-02
USP Class VI Materials
Medical-grade silicone (Wacker Silpuran 2400, Dow Sylgard 184) and TPE-V (Kraiburg Thermolast M) qualified to USP Class VI cytotoxicity for ISO 13485 patient-applied parts.
OVM-03
In-House Mold Shop
Sister mold-tooling shop on the same Cavite floor. Single-cavity prototype $800–$2K, multi-cavity production $3–12K NRE amortized over 5–10K units. 18–28 day tooling lead time.
OVM-04
50,000+ Flex Validated
Strain-relief geometry validated to 50,000+ flex cycles per IEC 60068-2-31 on the in-house chainflex bend rig. Igus CF38 / CF77 jacket compatibility designed in at the DFM stage.
OVM-05
IP67 / IP68 Sealed
Overmold strain reliefs designed to IP67 (1m × 30 min) and IP68 (continuous immersion) per IEC 60529. Validated at the test row immersion tank. Used on automotive sensor and PV harnesses.
OVM-06
Technical Specifications
Overmold Cell Datasheet.
| Shot Modes | Single-shot + Double-shot (two-color / dual-durometer) |
| Material — PVC | Standard semi-rigid 70–95 Shore-A; cost-down baseline |
| Material — TPE-S | Kraiburg Thermolast K · 55–80 Shore-A · UV-stable variants |
| Material — TPE-V | Kraiburg Thermolast M (medical) · 50–70 Shore-A · USP Class VI |
| Material — TPU | BASF Elastollan · abrasion + chemical resistance · 80–95 Shore-A |
| Material — Silicone | Wacker Silpuran 2400 / Dow Sylgard · 30–70 Shore-A · USP Class VI |
| Hardness Range | 30 Shore-A (silicone) to 95 Shore-A (TPU/PVC) |
| Cycle Time | 25–45 s typical (AWG and shot-volume dependent) |
| Cavity Count | Prototype 1-cavity; production typical 4 / 8 / 16 |
| Tooling NRE — Proto | $800–$2,000 (single-cavity, P20 steel) |
| Tooling NRE — Production | $3,000–$12,000 (multi-cavity, hardened H13) |
| Tooling Lead Time | 18–28 days from approved 3D file to first-shot |
| Tool Life | ≥1,000,000 shots on H13 hardened production tools |
| Flex Validation | 50,000+ cycles per IEC 60068-2-31 (chainflex rig) |
| Sealing Class | IP67 / IP68 per IEC 60529 (immersion validated) |
| Compliance | RoHS, REACH, USP Class VI on medical formulations |
Production tooling NRE amortized over 5,000–10,000 units. Visit /tooling for the full mold-tooling capability detail.
Overmold Process Flow
Six Steps. One Tool.
Design + DFM
Tooling engineer reviews harness drawing, recommends draft angles, gate location, parting line — typically 4–7 day DFM cycle with customer.
Tool Cut
In-house mold shop cuts P20 prototype or H13 production tool — 18–28 days from approved 3D STEP to first-shot. Customer signature required at first-piece review.
Insert Stage
Pre-terminated and Cirris-tested harness loaded into mold cavity by operator with insert-locating pin per fixture drawing; mold closes against insert geometry.
Inject + Cool
TPE/PVC/silicone injected at material-specific temp (180-220 °C TPE, 160-180 °C silicone). Hold + cool cycle 15-30 s; total cycle 25-45 s.
Eject + Trim
Part ejected, sprue/runner trimmed by operator under 10× lens. Flash inspected per IPC-A-620 §8 acceptance — none allowed at sealing surfaces.
Test + Validate
Post-overmold harness re-Cirris tested for any net damage during insert; IP67/IP68 immersion test on first-piece per shift. MES barcode includes mold cavity ID.
Where Overmolds Ship
Six Overmold Application Buckets.
Automotive Sensor Strain Reliefs
TPE-S overmold on TE MQS sealed connectors for ABS, O₂, and crank-position sensor harnesses — IP67 sealed.
Medical Patient Cables
USP Class VI silicone overmold on AWG 28 ECG and patient-monitor cables; autoclave-resistant variants on request.
Robotics High-Flex Drag Chains
TPU overmold on Igus chainflex CF38 / CF77 — 50,000+ cycle flex validated for cobot and AGV deployments.
EV / Solar Connector Boots
TPU/PVC boots on MC4 and HV battery connectors; UV-stable TPE-S grade for outdoor PV string runs.
Industrial M12 Field-Wireables
Single-shot overmold M12 male/female pigtails for PROFINET, EtherCAT, IO-Link factory networks.
Consumer Power & Data
Double-shot grip + boot for OEM consumer power adapters, USB-C/Lightning aftermarket assemblies.
Founder Note · Mr. Fei Bo Hu
“The reason we brought tooling in-house in 2024 was to kill the four-week dead zone between customer ECN and revised first-shot. When the tool, the overmold cell, and the harness fixture-board all sit on the same floor, an ECN turns in 4-7 days instead of 35. The tooling shop pays for itself roughly twice a year on saved program slips alone — never mind the NRE delta. If your overmold supplier doesn't own the steel, you're paying interest on every revision.”
— Mr. Fei Bo Hu · President · Xudong Group · XUDONG Philippines
Overmold Engineering FAQ
Six Questions
Buyers Always Ask.
Q.01What does in-house tooling actually save me on a real program?
+
What does in-house tooling actually save me on a real program?
Q.02Which material — PVC, TPE, TPU, or silicone — for what application?
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Which material — PVC, TPE, TPU, or silicone — for what application?
Q.03What's the practical hardness ceiling for single-shot strain reliefs?
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What's the practical hardness ceiling for single-shot strain reliefs?
Q.04Can you overmold a customer-supplied harness and connector, or only your stocked inventory?
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Can you overmold a customer-supplied harness and connector, or only your stocked inventory?
Q.05How do you validate flex life on a strain relief?
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How do you validate flex life on a strain relief?
Q.06What's the realistic cost crossover from prototype to production tooling?
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What's the realistic cost crossover from prototype to production tooling?
Related Industries
Where Overmold Strains Land.
Real Project Snapshot · US · marine · 2025-Q3 → 2026-Q1
A Build We Already Shipped In This Lane.
Scenario
A US marine OEM sought a new supplier for custom wire harnesses and audio systems, initiating a rigorous multi-month evaluation process involving multiple business units.
Challenge
The customer issued 6 separate RFQs over two months and engaged in a 64-email deep-dive technical thread, demanding strict weekly delivery, tariff mitigation, and cost competitiveness compared to incumbent suppliers.
Outcome
Successfully navigated the extensive qualification process, secured the tooling order, and transitioned into the prototyping phase for mass production.
Anonymized customer detail. Concrete numbers preserved verbatim.
Group Tooling Support
Group-Backed Mold Engineering Depth
Overmolding tooling at XUDONG Cavite is backed by group mold engineers who work beyond simple connector boots. Their benchmark projects include 96-cavity bottle cap molds for repeatable precision, motor-driven thread extraction molds used in medical-grade parts, hot & cool injection molds, double-injection layouts for two-color parts in a single mold set, and 3D-printed metal or plastic mold inserts for fast prototype validation.
That capability stack matters when a harness customer asks for an overmold with integrated grip texture, a color split, sealing ribs, or a revised cable-exit angle. Those are routine techniques on the group's mold-shop floor, so the harness team can quote the assembly, tooling approach, DFM constraints, and validation plan together instead of passing the overmold detail to an unrelated outside supplier.
Next Step
Quote The Tool And The Harness Together.
Send harness drawing + connector list. We'll return tooling NRE, per-piece amortized cost across 3 volume tiers, and DFM call-outs in 7 working days. Quote returned within 12 hours. NDA on file. No obligation.