Overmolding

Cable Overmolding Services

Kato Cable provides cable overmolding services that improve the strength, protection, and appearance of cable assemblies. Using materials like thermoplastic and thermoset, we mold over connectors and cables to shield them from moisture, chemicals, and mechanical stress.

Our overmolded assemblies are built for demanding environments and customized to meet the needs of OEMs in the automotive, electronics, and industrial equipment industries.

High Pressure Overmolding

High Pressure Overmolding uses traditional injection molding machines, involving high injection pressures (typically 10,000–30,000 psi).


Materials used are typically thermoplastics like ABS, PC, Nylon, TPE.


Strong adhesion between materials, high durability, and mechanical strength make High Pressure Overmolding necessary in rugged environments.

Low Pressure Overmolding

Lower Pressure Overmolding uses much lower injection pressures (500–5,000 psi).


Typically uses polyamide-based hot melt materials.


Typical uses are for encapsulating delicate electronics, PCBs, sensors, and connectors. Mainly used in medical, automotive, and consumer electronics.

Benefits of Cable Overmolding

Cable overmolding enhances functionality, aesthetics, and long-term performance. It plays a critical role in protecting sensitive terminations, simplifying installation, and ensuring dependable operation in real-world applications. We focus on precision and consistency to deliver assemblies that meet exacting standards every time.

Sealed Protection

Shields connections from moisture, dust, and chemicals.

Strain Relief

Reduces cable stress and helps prevent wire fatigue.

Durable Performance

Withstands vibration and harsh operating conditions.

Consistent Quality

 Maintains uniform coverage and reliable results.

Faster Installation

Simplifies assembly and reduces handling time.

Custom Options

Allows for molded logos, colors, and ergonomic shapes.

Reduced Maintenance

Minimizes service needs and extends product life.

Process Control & Engineering Control Services

Process Control

Precision and consistency are at the heart of every custom cable solution. Our Process Control strategies ensure each assembly meets exact specifications, from initial concept to final production. Through rigorous quality checks, standardized procedures, and real-time monitoring, we optimize efficiency while maintaining the highest level of reliability.

Engineering Control

From concept to completion, Engineering Control ensures every design is optimized for functionality, manufacturability, and long-term performance.  Our expert team evaluates form, fit, and function, applies industry best practices and testing protocols, and leverages innovative solutions to deliver high-quality and cost-effective cable and harness assemblies.

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Our Products are Proudly Made in the USA

Industries We Serve with Custom Cable Overmolding

Kato Cable works with OEMs in sectors where dependable electrical connections are essential. Our overmolded assemblies are engineered to perform reliably in high-impact, high-use environments.


We support:

Automotive: Robust assemblies for lighting, control systems, and under-hood electronics.

Electronics: Precision-molded cables for sensors, signal routing, and embedded systems.

Industrial Equipment: Reinforced solutions for power distribution, control panels, and automation.

Emergency Vehicles: Reliable wiring for fire trucks, service fleets, and specialty applications.

Marine and Recreation: Moisture-resistant assemblies for onboard systems and exposed components.



Our experience across these industries allows us to meet unique challenges with tailored overmolding solutions that improve product life and streamline integration.

The Kato Cable Advantage

The Kato Cable Advantage is a holistic approach to looking at the value that you bring to your customers, employees and community. Our customers relate directly to our responsiveness and engineering value, to the investments that we have made into efficiencies and automation, and to the key metrics of industry leading Quality and On Time Delivery. Our employees relate to a sense of inclusion, an appreciation and value to feedback, and the philosophy of making improvements every day. Our community relates to our growth and volunteerism and leadership that we strive for in our region. Together these attributes and values truly deliver the Kato Cable Advantage!

Quality & Reliability

Delivering precision-engineered wire harnesses, cable assemblies, and electro-mechanical assemblies that meet the highest industry standards.

Innovation

Continuously improving processes and technologies to provide cutting-edge solutions for diverse industries.

Customer Commitment

Building strong partnerships through collaboration, responsiveness, and tailored solutions.

Our Certifications

Stay Connected with our Blog

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Over Molding Contact Us

Looking for Support?

Launching a new product? Improving an existing design? Kato Cable is here to help. We collaborate with OEMs to deliver overmolding solutions that increase reliability, simplify installation, and perform in demanding environments.