Overmolding cable assemblies for the defence industry

Overmolding for Military Standard Cables

What is Overmolding?

Overmolding is a specialized manufacturing process that involves applying a layer of material over a substrate, typically another type of plastic or metal. This technique enhances the durability, functionality, and appearance of the final product. Overmolding is particularly beneficial in the military sector, where products must meet rigorous standards for performance and reliability.

Why Choose Cornelius Electronics for Military Overmolding?

Cornelius Electronics has 40 years of experience in providing high-quality overmolding services, including solutions tailored for military applications. Our team of over 250 IPC-trained operatives operates from a cutting-edge 50,000 square foot facility in the UK. We specialize in high-mix, medium-volume production, ensuring that each product meets exacting military standards.

Defence grade overmolding services
Defence grade overmolding services

Benefits of Overmolding Military Products

  1. Enhanced Durability: Overmolding adds a protective layer that can withstand extreme conditions, including high impact, abrasion, and harsh environments.
  2. Improved Functionality: Overmolded products offer better grip, insulation, and resistance to moisture and chemicals, essential for military use.
  3. Customization: Overmolding allows for precise customization, enabling the production of components that meet specific military specifications and requirements.
  4. Aesthetic and Tactical Advantage: The process allows for complex designs and finishes, which can include camouflage patterns and other tactical enhancements.

Our Overmolding Services for Military Products

Cornelius Electronics offers comprehensive overmolding services designed to meet the stringent requirements of military applications. Our capabilities include:

  • Material Selection: We assist in selecting materials that offer the best performance under extreme conditions, including high-strength plastics and specialized coatings.
  • Design and Engineering Support: Our experienced engineers work with you to design molds that optimize functionality and durability for military use.
  • Prototyping and Testing: We provide rapid prototyping services to test and refine designs, ensuring they meet military standards before full-scale production.
  • Production: Our facility is equipped for high-mix, medium-volume production, ensuring consistency and reliability across all units.
  • Quality Assurance: Rigorous testing and inspection processes are in place to ensure every overmolded product meets or exceeds military specifications.

Military Applications

Cornelius Electronics provides overmolding solutions for a wide range of military applications, including:

  • Weapon Components: Overmolding enhances the durability and functionality of weapon grips, handles, and other critical components.
  • Electronic Enclosures: Protect sensitive military electronics from environmental factors and physical damage with robust overmolded enclosures.
  • Connectors and Cables: Improve the reliability and performance of military connectors and cables with overmolding that ensures secure and durable connections.
  • Protective Gear: Enhance the comfort and effectiveness of military protective gear with custom overmolding solutions.

Why Partner with Cornelius Electronics?

  1. Experience and Expertise: With 40 years of industry experience, we have the knowledge and skills to deliver superior overmolding services tailored for military applications.
  2. State-of-the-Art Facility: Our 50,000 square foot production facility is equipped with the latest technology and staffed by over 250 IPC-trained operatives.
  3. True Partnerships: At Cornelius Electronics, our core value is building true partnerships with our clients. We work closely with you to understand your needs and deliver solutions that exceed your expectations.
  4. High-Mix, Medium-Volume Production: We specialize in high-mix, medium-volume production, providing flexibility and efficiency for diverse project requirements.
Cornelius Electronics