Strain reliefs
Tapered boots that stop cables snapping at the connector.
Overmoulding · Cable and connector overmould
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 load and makes the join look like it was meant to be there.
The detail
Why silicone for cables
Silicone stays flexible in the cold, tolerates heat, and bonds to many cable jackets with the right preparation. That makes it a good choice for medical leads, outdoor sensors, marine equipment and anything that gets flexed thousands of times.
The design work is in the transition: how stiff the overmould is at the connector end, how it tapers towards the cable, and how it grips the jacket so water can't wick along underneath.
Where it fits
Typical jobs
Sealed connectors
Overmoulded connectors for wet and washdown environments.
Breakouts and splices
Where one cable splits into several, sealed in one body.
How we run it
How we run it
Cable and jacket review
Jacket material, diameter tolerance and heat limits checked.
Tool with cable clamping
The tool grips the cable to seal the cavity and hold position.
Mould at a safe temperature
Grade and cure chosen so the cable and connector aren't damaged.
Pull and continuity checks
Strain and electrical continuity checks agreed with you and recorded.
To quote it
To quote it
Sample cable assemblies
Including some for trials we can cut up.
Environment
Water, UV, oils, temperature, flexing.
The look you want
Colour, texture, any moulded logo.
Your test
Flex cycles, pull force or ingress test.
At a glance
The ideas in pictures.
How overmoulding works
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From drawing to delivered parts
- 01Drawing or sampleYour part and where it is used
- 02Material and routeCompound and process agreed
- 03PrototypeReal parts to test
- 04Sign-offYou approve the samples
- 05Production toolBuilt for your volumes
- 06Batches and checksInspected and delivered
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Questions
What people usually ask.
Do you make the cable assemblies too?
We overmould assemblies supplied by you or by a partner. We can coordinate the whole assembly through our partner network if that's simpler.
Is silicone better than PVC or TPU for this?
For flexibility, temperature range and feel, often yes. For abrasion resistance, not always. We'll talk it through.
Keep exploring
More from overmoulding.
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Back to the overviewDesigned and developed in the UK. UK moulding capability, with some higher-volume production placed with trusted partners where that's the right commercial answer.
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