Custom Military Overmolded Assemblies Manufacturing Services

As a leading manufacturer of precision-engineered connections for the most challenging industries and environments, Winchester Interconnect is a leading supplier of custom military-grade overmolded assemblies. Overmolding involves using various types of resin to encapsulate the wire and connector into a single, sealed piece that exhibits outstanding strength and durability. Overmolded assemblies provide increased flexibility, 360° strain relief, resistance to shock and abrasion, and protection in harsh environments. With our engineering strength, we manufacture the highest value environmentally sealed cable assemblies in the shortest lead times. Our multi-disciplinary technical team uses the latest 3D modeling and simulation tools to analyze performance, and we leverage 3D printing technology to produce samples. We offer the industry’s largest selection of RF connectors and a wide variety of shielding options. Our standard tooling includes straight, right angle, and 45° molds compatible with the most popular military connector families. Molding materials consist of various elastomers, polyurethanes, and glass-reinforced epoxies, all available in multiple colors to facilitate identification. Along with Mil-grade USB cable, we manufacture megabit and gigabit Ethernet cables and straight and coil cord configurations. We create semi-rigid to high-performance flexible assemblies for high frequency to high power applications in temperature ranges of -55°C to + 105°C. Some examples include military ground vehicles, mobile and tactical communications systems, ruggedized networking, weapons systems, ground-based radar, drones, and more. We provide AS9100D quality assurance, and our products conform to IPC/WHMA-A-620 (Class 3) standards. For more information about our custom military-grade overmolded cable assembly manufacturing or to request a quote, contact us directly.