Molded connectors and harness assemblies are often used with sensors and control devices that require easy disconnection. Although molded connector and harness assemblies solutions are widely available, standard products do not always fully meet application requirements. Because each application has its own unique set of operating characteristics, a single product cannot be accommodated, which is why so many components choose to customize. This article mainly introduces five points to consider when custom-molding connectors and harness assemblies!

Molded connector assembly

1. Material selection of connecting nut and socket body
Moulded connectors and harness assemblies are used in a variety of environments, many of which are harsh and extreme, and the choice of materials should be based on the specific environmental needs of specific applications. The following are the five materials commonly used to connect nuts and container bodies:

1. Anodized aluminum, suitable for most industrial applications.
2. Stainless steel, suitable for severe corrosive environment.
3. Non-metallic, most suitable for mildly corrosive applications.
4. Nickel-plated brass, corrosion-resistant, in line with EMC requirements.
5. PEEK? Polymer, suitable for high temperature or high water pressure applications.

2. Overmolding and cable material selection
Injection molding allows overmolded wire components to be produced in any shape or contour, as well as various materials, colors, surface treatments and designs. These products can significantly improve environmental performance characteristics and component reliability and finished product applications. Common material choices include:
1. Rubber, most suitable for extreme temperature and hot substrate applications, such as welding spatter, and applications exposed to solvents, oils and coolants.
2. Silicone, most suitable for high temperature applications.
3. PVC is most suitable for general industrial applications.
4. Polyurethane (PUR) provides excellent wear resistance for applications exposed to mechanical abuse.
5. Thermoplastic elastomer (TPE), which has excellent chemical resistance and wear resistance in harsh environment applications.

3. Installation and connection options
Another part of the customization process involves choosing from various installation options and connection methods. Socket housing options include flange mounting, panel mounting, rear panel mounting, board mounting and SAE or metric threads. For the coupler, please select the internal thread, external thread or adapter options to provide flexibility in any style. Accessories such as covers, panel gaskets and O-rings are also available. These cable connection and installation possibilities give custom molded connectors and wire sets great design flexibility and allow users to choose the most suitable for quick installation, low maintenance, easy maintenance, enhanced environmental resistance, high performance and long life Individual components.

4. Special wiring
Fully customized molded connectors and wire assemblies can be easily produced with special wiring configurations to meet specific application requirements. Special wiring options include parallel wiring, series wiring, combined wiring (one side is in parallel and the other side is in series), interlock circuit wiring and customer-specified wiring.

5. Customized packaging and accessories
Molded connector and harness assembly solutions can also be customized for packaging, matching and labeling. Packaging options may include heat-sealed packaging to ensure that all contents are kept together, reclosable packaging to allow access to individual components, and bulk packaging for easy storage in inventory. Custom accessories can group multiple components under a single SKU to enhance organization, reduce the use of packaging materials, reduce inventory and order errors, and increase overall efficiency. In addition, custom labels with barcodes, logos, shelf locations, content lists, and item numbers can enhance organization and brand consistency.

    Custom molded connectors and harness assemblies can make installation easier, require less maintenance, have higher reliability, and have precise application-specific properties, and allow mixing and matching from a variety of materials, installation, connection, wiring, packaging, Components with matching and labeling options to develop molded connectors or cable assemblies that are fully adapted to specific application needs. Depending on the level of customization required and the cost of applications and components, it is usually a more cost-effective solution than expected.

After reading the above, I believe everyone should understand the five factors that need to be considered when custom-molding connectors and harness assemblies.