Overmolded Wire Harness
TPE OVERMOLD.
IN-HOUSE TOOLING.
50K-CYCLE FLEX.
Single and double-shot overmolded wire harnesses from Cavite. TPE 65-95 Shore-A, PVC 80-95 Shore-A, TPU on request. In-house mold shop cuts the tool — 18-25 days from approved 3D model to first shot. Tool ownership transfers to the customer.
50K+
Flex Cycles
65-95
TPE Shore-A
2-Shot
Tool Capable
18-25 D
Tooling Lead
TPE / PVC
Material library
In-House
Mold shop
50K+
Flex life cycles
Class 3
IPC-A-620 default
When To Overmold
ONE COMPONENT.
THREE PROBLEMS SOLVED.
A TPE overmold solves three otherwise-separate problems in a single shot: strain relief at the cable-to-connector transition (extending flex life from roughly 5,000 cycles to 50,000+), IP67 to IP69K sealing of the wire entry, and aesthetic / ergonomic finish on consumer-facing parts. The Cavite mold shop cuts the tool, the harness line runs the harness, and the same operator supervises both — there is no factory handoff and no separate quality system between the cable build and the molded part.
If your need is purely sealing without a flex requirement, see waterproof harness — a sealed connector may be cheaper than a custom tool. If the harness is HV (charge gun, traction cable), see high-voltage harness — overmold geometry differs for orange-jacket cable. For the unconstrained custom baseline, see custom wire harness. Tooling capability lives at tooling & mold.
Overmold Capability Block
FROM 1 G SHOTS
TO 220 G BOOTS.
TPE 65-95 Shore-A Range
Active material library: Kraiburg Thermolast K (65-90 Shore-A), Mitsui Milastomer (75-95 Shore-A), Teknor Apex Monprene (60-80 Shore-A). Selection driven by flex life, chemical exposure, and adhesion target — not by what is on the shelf.
PVC 80-95 Shore-A
PVC overmold for cost-sensitive consumer and appliance harnesses. Lower-temp processing (165-180 °C barrel) and 30-40% lower material cost than TPE. Shore-A 80-95 covers strain relief on USB, audio and medical lead-wire applications.
Single & Double-Shot Tooling
Single-shot for monolithic strain relief on cable-to-connector transitions. Double-shot (2K) for soft-rigid combinations — hard PA66 backbone with TPE overlay grip. In-house mold shop cuts both, 18-25 days from approved 3D model to first shot.
50,000+ Flex Cycle Life
Strain-relief overmolds tested per UL 758 §4.2 flex schedule and IEC 60227-2: 50,000 cycles minimum, 200,000 cycles for robotic drag-chain applications. Failure mode is jacket fracture at the boot interface — our default fillet radius is 4× cable OD.
Dedicated 50T / 100T Presses
Two Sumitomo SE-50EV electric presses for low-shot-weight precision (1-30 g shots), one Sumitomo 100-tonner for larger boot geometry. Cycle time 35-55 seconds per shot. CFM cavity-pressure monitoring on every cavity.
Void-Free X-Ray Sampling
First 50 shots of every new tool X-rayed for internal voids and weld-line position verification. Pull-test on the cable-to-overmold bond targets 100 N minimum on a 1.5 mm² cable. Adhesion failures get fed back into nozzle-temperature retune.
Specification Sheet
OVERMOLD
ENVELOPE.
TPE Materials
Kraiburg Thermolast K, Mitsui Milastomer, Teknor Apex Monprene
PVC Materials
Sun PVC, Tarflex, Wacker compounds (80-95 Shore-A)
Hardness Range
TPE 60-95 Shore-A · PVC 80-95 Shore-A · TPU 70-95 Shore-A on quote
Shot Weight
1 g to 220 g per shot · Sumitomo SE-50EV (≤30 g) and SE-100 presses
Cycle Time
35-55 seconds per shot · CFM monitor on every cavity
Tooling Lead
18-25 days cut-to-first-shot · cavity counts 1×, 2×, 4× and 8×
Tooling Cost
USD 600-2,400 per cavity · ownership transfers to customer
IP Rating Capability
IP67 standard · IP68 immersion · IP69K spray-down on TPE
Operating Temp
−40 °C to +110 °C TPE · −15 °C to +85 °C PVC · −40 to +125 TPU
Flex Life
50,000 cycles standard · 200,000 cycles drag-chain class on quote
Bond / Pull Test
100 N minimum on 1.5 mm² cable · IPC Class 3 acceptance
Acceptance Class
IPC/WHMA-A-620 Class 3 default
Production Lead
Sample 7-10 days post tool · Production 10-15 days
MOQ
1 piece sample · 200 piece production tier · 2,000 volume tier
Tool To Production
3D MODEL TO
FIRST SHOT.
3D Geometry & DFM
Send STEP / IGES of overmold geometry. Engineering replies in 12 h with quote, gating recommendation, draft angle review, and material call.
Tool Cut
Tool cut in our in-house mold shop. P20 steel for 100K-shot tools, 718H for 500K, NAK80 for high-finish. 18-25 days to first shot.
First-Shot Sampling
First 50 shots X-rayed for voids and weld-line position. Cable-to-overmold pull tested at 100 N minimum. Tool tweaks per the X-ray report — usually 1-2 spotting passes.
Production Mold
Sumitomo SE-50EV electric or SE-100 hydraulic press, CFM cavity-pressure monitor on every shot. Cycle time logged, deviations greater than 7% pause the cell.
100% Test
Cirris continuity, HiPot, dielectric. AQL 0.65 dimensional check on overmold geometry. Strain-relief flex test on first lot of every new program.
Pack & Ship
Tray-packed, vacuum-sealed. FOB Manila MICT. Form A on every commercial invoice. Tool ownership transfers to customer on request.
Application Map
SIX OVERMOLD
USE CASES.
USB / Audio / Charger Cable
Consumer-grade PVC strain relief on Type-C, Lightning, audio jack. 80-90 Shore-A, 50K-cycle flex life, custom PMS color matching.
Medical Lead Wire
ISO 13485 cleanroom build. Medical-grade TPE (Kraiburg HC series), latex-free, ETO sterilizable. ECG, EEG and patient-monitor lead wires.
Robotic Drag-Chain Cable
Track-chain TPE overmold with 200K-cycle flex life. JIS C 3406 tinned-copper braid inside. Cobot, AGV, and AS/RS umbilical.
EV Charging Connector Boot
TPE overmold on CCS / CHAdeMO / NACS connector backshells. UV-stable, 80 °C ambient rated, IP67 mating sealing.
Industrial Sensor Pigtail
M8 / M12 / 7/8-inch sensor pigtails with TPE overmold for IP67 sealing and strain relief. PROFINET, EtherCAT and IO-Link variants.
Appliance Power Cord
PVC overmold on IEC C13 / C14 / Schuko power cords. UL 62 / VDE / CCC certified material library.
Founder Note
“Overmold tooling is where most contract shops outsource. We cut ours in the same Cavite campus as the harness line — cycle time drops from 6 weeks of vendor management to 18-25 days, and tool spotting feedback loops in 24 hours instead of 5 days. That is the entire reason an EV charge gun program lands at our door instead of a Vietnamese competitor's.”
Mr. Fei Bo Hu
President · Xudong Group · XUDONG
Overmold FAQ
SIX QUESTIONS
ENGINEERS ASK.
Q.01When should I overmold instead of using a strain-relief boot?
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When should I overmold instead of using a strain-relief boot?
Q.02TPE versus PVC versus TPU — which do I pick?
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TPE versus PVC versus TPU — which do I pick?
Q.03What is the realistic tooling lead time and cost?
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What is the realistic tooling lead time and cost?
Q.04Can you do double-shot (2K) overmolds?
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Can you do double-shot (2K) overmolds?
Q.05Do overmolds always need a custom tool?
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Do overmolds always need a custom tool?
Q.06What documentation comes with an overmolded production run?
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What documentation comes with an overmolded production run?
Related Services
ADJACENT
CAPABILITIES.
Tooling & Mold
In-house mold shop. Single, double-shot and stamping dies, 18-25 days cut-to-first-shot. Tool ownership stays with the customer.
Read moreOvermolding Capability
The capability detail behind the product. Press list, material library, X-ray QA, flex test bench.
Read moreWaterproof Harness
TPE liquid-injection overmold is the cleanest path to IP69K spray-down sealing. Validated 96 h salt fog.
Read moreWhere It Ships
OVERMOLD HARNESS
VERTICALS.
Medical Devices
ISO 13485 cleanroom build. Medical TPE, USP Class VI, ETO sterilizable lead wires.
See industryRobotics & Automation
200K-cycle drag-chain TPE umbilicals. Cobot, AGV, AS/RS umbilical and feedback cables.
See industryAutomotive & EV
EV charge connector boots, sensor pigtails, drive-by-wire harness strain reliefs. IATF 16949.
See industryOvermold Programs
Overmolded Cable Assemblies · TPE / PVC In-House.
Single-shot overmold up to 65 Shore-A on cable strain reliefs, in-house mold tooling rated 50,000+ flex cycles.
Panel-mount jack to JST
Threaded panel mount + JST signal lead
Two-wire open-end JST pigtail
Short pigtail with overmold strain relief
LED module strip jumper
Overmolded LED module on 12 V harness
Real Project Snapshot · US · automotive · 2026-Q1
A Build We Already Shipped In This Lane.
Scenario
A US commercial EV manufacturer reported a quality escape where a specific harness was built with an incorrect connector.
Challenge
The specified part number for connector C49C-F (DTCE06-1-8S-E003) was swapped for a different component, causing a specification mismatch and halting the customer's assembly line.
Outcome
Resolved the quality escape rapidly; the customer continued placing high-volume production orders despite the initial setback, demonstrating restored trust.
Anonymized customer detail. Concrete numbers preserved verbatim.
Reviewed by Hommer Zhao- Cavite-based wire harness engineer at XUDONG, IPC/WHMA-A-620 Class 3 trained, 8+ years in automotive & medical harness manufacturing.
Next Step
Send The 3D Model. We Cut The Tool.
TPE / PVC / TPU material library on site. 18-25 days cut-to-first-shot. Tool ownership transfers to you. Quote returned within 12 hours. NDA on file. No obligation.