When an assembly has to survive water, dust, vibration and temperature, the IP-Rated seal is everything. Cornelius Electronics designs and manufactures IP68 rated, overmoulded cable assemblies in the UK – sealed at the point it matters most, the join between cable and connector – so your product keeps working where others let water in.
We are a sub-contract manufacturer based in Port Talbot, South Wales, with 40+ years’ experience and an in-house overmoulding facility built specifically for sealed, ruggedised assemblies. From first concept to tooling to finished, tested parts, you get one UK partner accountable for the whole job.
What an IP rating actually means
“IP” stands for Ingress Protection. The two digits tell you how well an enclosure keeps out solids and liquids: the first (0–6) covers dust, the second (0–9K) covers water. IP68 – the rating our overmoulding is built to – means fully dust-tight and protected against continuous submersion in water. New to IP ratings? Our plain-English guide explains IP67 vs IP68 in full. (internal link to the explainer page).
IP68 overmoulding, designed and made in-house
We’ve invested over £500,000 in a six-station overmoulding facility, with both low-pressure and high-pressure capability under one roof. Low-pressure overmoulding protects delicate components with gentle, precise sealing; high-pressure handles tougher, higher-volume work. Because the design, tooling and moulding all happen in-house, we control the quality of the seal end to end – and keep your lead times short.
- Low-pressure and high-pressure overmoulding in one facility
- In-house design capability – concept through to tooling design
- IP68-rated sealing for water and dust ingress protection
- Built-in strain relief and ruggedisation for demanding environments
Built for demanding environments
Defence, transport, industrial and outdoor applications all share one problem: the cable assembly is usually the weak point. Overmoulding removes that weak point by sealing and strengthening the connection in a single moulded part – no glands to loosen, no boots to perish. The result is an assembly that shrugs off water, dust, shock and vibration in the field.
From design to delivery, with one UK partner
You don’t need to coordinate a separate design house, tool-maker and assembler. Our engineers take your requirement from concept to a manufacturable, sealed design, build the tooling, and deliver finished assemblies – fully tested. Onshoring the work to a UK partner means shorter supply chains, faster iterations, local accountability and a smaller carbon footprint.
Quality you can certify against
Our quality systems are built for regulated industries:
| Standard | What it means for you |
| AS9100D | Aerospace-grade quality management, the benchmark for defence and aviation supply. |
| ISO 9001 / ISO 14001 | Certified quality and environmental management. |
| IPC/WHMA-A-620 | The recognised standard for cable and wire harness assembly workmanship. |
| IPC Class 1 / 2 / 3 | Workmanship to the class your application demands, up to Class 3 for high-reliability military and aerospace. |
With 200+ IPC-trained operators producing around 11 million assemblies a year, the capacity and consistency are already in place.
Why have it made in the UK?
UK manufacture isn’t just a flag on the box. It means reduced supply-chain risk, a partner you can visit and call, faster prototyping, and a smaller carbon footprint than shipping assemblies halfway around the world. For defence and security work it also keeps sensitive manufacturing onshore.
Talk to our team
Need an IP68 cable assembly that survives the field?
Send us your requirement and our engineers will tell you how we’d seal it. Contact us
Frequently asked questions:
What is an IP68 cable assembly?
A cable assembly sealed to IP68 – fully dust-tight and protected against continuous water submersion, usually achieved by overmoulding the connection between cable and connector.
What’s the difference between IP67 and IP68?
Both are dust-tight; IP67 withstands temporary immersion (around 1m for 30 minutes), while IP68 is rated for continuous submersion at greater depth. See our full IP67 vs IP68 guide.
Can you design the assembly for us?
Yes, we have in-house design capability and take projects from concept through tooling to finished, tested parts.
Are you certified?
Yes – AS9100D, ISO 9001, ISO 14001 and IPC/WHMA-A-620, with workmanship to IPC Class 1, 2 or 3.