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Custom Molded Cable Assemblies

Your Connection to Quality, Durability, and Performance

In a world where connectivity is the backbone of technological advancement, Circuit Assembly is proud to introduce our bespoke Molded Cable Assemblies, engineered to power your projects with unparalleled reliability and performance. Our custom solutions are designed to meet the rigorous demands of industries seeking perfection in every connection.

Why Choose Our Molded Cable Assemblies?

Customization to Fit Your Needs

Every project is unique, and so should be every solution. At Circuit Assembly, we specialize in providing tailored cable assemblies that perfectly match your specifications, environment, and application requirements. Whether it’s for aerospace, medical, automotive, or telecommunications, our team works closely with you to design and manufacture cables that fit like a glove.

Enhanced Durability

Our molded cable assemblies are not just built; they’re fortified. The molding process encases wires in a protective shell, safeguarding them against physical stresses such as bending, stretching, and crushing. This protective armor ensures longevity and reliability in the most demanding environments, from the depths of the ocean to the vastness of space.

Superior Performance

Quality is not an act at Circuit Assembly; it’s a habit. Our molded cables are designed for optimal signal integrity and power efficiency. With advanced materials and precision manufacturing, we ensure minimal signal loss and maximum performance, keeping your systems running smoothly and efficiently.

Fast Turnaround Times

Innovation waits for no one. That’s why we pride ourselves on our swift production capabilities. Our streamlined processes and expert team enable us to deliver your custom molded cable assemblies quickly, without compromising on quality. Stay ahead of the curve with solutions that arrive when you need them.

Types of Molded Cable Assemblies

Molded cable assemblies come in various types to serve a broad range of applications and industries. Each type is designed to address specific requirements, including environmental conditions, electrical specifications, and mechanical stresses. Here are some of the key types:

Overmolded Cables

Overmolded cables feature a thermoplastic or thermoset covering, which is molded over the cable and connector to enhance durability and resistance to environmental factors. This process offers improved strain relief, sealing against moisture and dust, and increased strength compared to standard cable assemblies.

Custom Harness Assemblies

Custom harness assemblies are complex configurations of wires and cables bundled together to improve organization, reduce space, and simplify installation. These are often overmolded to protect against wear and tear, environmental exposure, and electromagnetic interference (EMI).

Ruggedized Assemblies

Designed for extreme conditions, ruggedized assemblies are built to withstand harsh environments such as high temperatures, corrosive substances, vibration, and shock. They are typically used in military, aerospace, and industrial applications.

Waterproof Assemblies

Waterproof molded cable assemblies are specifically designed to prevent water ingress, making them ideal for marine, outdoor, and underwater applications. These assemblies often adhere to specific IP (Ingress Protection) ratings to certify their level of waterproofing.

Applications and Industries Served

Molded cable assemblies find their applications across a wide array of fields, each with its specific requirements and challenges. Here are some of the primary applications and the industries that benefit from these specialized solutions:

Aerospace and Aviation

In the aerospace and aviation industry, reliability and precision are paramount. Molded cable assemblies are used in aircraft systems, ground support equipment, and control towers for communication, navigation, and power distribution. Their durability and resistance to environmental factors make them essential in this high-stakes field.

Medical Devices

Medical devices require high-quality, reliable connections that can withstand sterilization processes and exposure to bodily fluids. Molded cable assemblies are used in diagnostic equipment, surgical instruments, and patient monitoring systems, offering the necessary durability and safety for medical applications.

Automotive and Transportation

The automotive industry utilizes molded cable assemblies in engine controls, infotainment systems, and sensor applications. These assemblies are designed to resist vibrations, fluctuations in temperature, and exposure to chemicals, ensuring the reliability and longevity of automotive components.

Industrial Automation

In industrial automation, molded cable assemblies are crucial for connecting sensors, actuators, and control units. They offer protection against dust, moisture, and mechanical stress, ensuring consistent performance in factories, processing plants, and other industrial settings.


Molded cable assemblies in the telecommunications sector are vital for data transmission and infrastructure connectivity. They are designed to offer superior signal integrity and protection against environmental conditions, supporting the backbone of global communication networks.

Marine and Underwater Applications

Marine and underwater applications demand waterproof and corrosion-resistant cable assemblies. Molded cables are used in subsea exploration, marine research, and naval operations, providing reliable performance in the challenging conditions of marine environments.

Renewable Energy

In the renewable energy sector, including wind, solar, and hydroelectric power generation, molded cable assemblies are used to withstand environmental challenges while ensuring efficient power transmission and connectivity.

Unwavering Support

From concept to completion, our support team is with you every step of the way. We offer expert advice, design assistance, and post-sale support to ensure your project’s success. With Circuit Assembly, you’re not just getting a supplier; you’re gaining a partner dedicated to your success.

Elevate Your Projects with Circuit Assembly’s Molded Cable Assemblies

Take the first step towards uncompromised connectivity and performance. Contact us today to discuss your custom cable assembly needs and discover how Circuit Assembly can bring your project to life.