Connector and cable overmoulds
Sealed, strain-relieved cable joints for sensors and lighting.
For marine and outdoor equipment makers
For marine and outdoor.
Salt spray, UV, freezing nights and hot decks. Outdoor equipment ages faster than anything else we make parts for, so the material choice comes first.
The environment decides
Outdoors, the wrong rubber fails quietly and then all at once.
Many rubbers look fine on the bench and crack after a season in the sun. Others stiffen in the cold, or swell when they meet fuel or sunscreen. For outdoor products, choosing the compound is most of the engineering.
Silicone and EPDM are our usual starting points: both handle UV and weather well, and silicone stays flexible across a very wide temperature range. Where fuels or oils are involved, we look at fluorosilicone or nitrile blends instead.
From there, the parts are familiar: ingress seals, cable overmoulds, grips, boots and bumpers. What changes is how we test them.
What outdoor makers need
Three recurring requirements.
Materials that age well
Compounds chosen for UV, ozone, salt and temperature cycling, with supplier data to back the choice.
Seals that keep recovering
Sections designed so seals spring back after years of compression and cold.
Hardware that stays put
Stainless inserts and fixings moulded in, not glued on.
What we make for outdoor kit
Four common parts.
Enclosure seals and boots
Seals for housings, switches and hatches.
Grips and bumpers
Soft grips and impact protection. See grips and handles.
Diaphragms and valves
Pressure-equalising and drainage parts. See diaphragms.
How we'd deliver
The services this sector uses most.
Cable and connector overmoulding
The point where a cable enters a connector or device is where most cables fail. An overmoulded silicone body seals that point, spreads the bending…
See the serviceIngress protection seals
Outdoor sensors, washdown controls and portable devices all need to keep water and dust out. The seal usually decides whether they do.
See the serviceHardware encapsulation
Wrapping a sensor, board or cable joint in silicone protects it from water, dust, vibration and hands. Done badly, it cracks solder joints or cooks…
See the service
Other sectors
Where else we work.
Designed and developed in the UK. UK moulding capability, with some higher-volume production placed with trusted partners where that's the right commercial answer.
At a glance
The idea in a picture.
How overmoulding works
Swipe to see the whole diagram
Get in touch
Tell us the part, the volume, and the timeline.
Rough annual volume, target unit price, and any deadlines. That's enough to work out whether compression, LSR injection or something else is the right tool.
Real people, a real workshop
You deal with the people who make it.
No call centre and no middlemen. When you contact TCI Products, you speak to the team who design, build and check your mould.
- A real Warwickshire workshopUnit 15, Waterloo Park, Bidford-on-Avon, Alcester B50 4JG.
- Real people on the phoneCall the team on 01789 224228, Monday to Friday.
- The same team on every jobDesign, production and aftercare come from the people you see here.
- Part of TCI GroupFive specialist brands, one engineering team. Visit TCI Group.
Thomas LaneManaging Director
George PrestonDesign & Project Manager
Kelly BallingerHead of Partnerships
Jim AndertonProduction Manager
TheodoreEmployee Welfare