Epec's Blog | Electronics Manufacturing Solutions

Cable shielding plays an important role in protecting electrical signals from electromagnetic interference, but not every cable assembly requires the same level of protection. Adding a shield can improve signal integrity and reduce susceptibility to interference, but it can also increase cable diameter, stiffness, cost, and assembly complexity.

At the conclusion of our webinar, Tips for Designing Custom Cable Assemblies Used in Medical Diagnostics Equipment, we had several questions submitted to our presenter, Epec Product Manager Team Lead Steven J. Goodman. We compiled these into a readable format on our blog.

Military and aerospace systems operate in some of the harshest environments imaginable. Whether installed on a military ground vehicle, commercial aircraft, unmanned aerial system, naval vessel, or satellite subsystem, cable assemblies are routinely exposed to vibration, shock, temperature extremes, moisture, harsh chemicals, and electromagnetic interference. In these applications, reliability is not simply desirable, it is essential.

There are few things more frustrating than finding out a connector, terminal, header, or small cable assembly component is no longer available. On the surface, it may seem like a simple sourcing issue. One part went obsolete, so you find another one and move on.

When it comes to cable assemblies and wire harnesses, consistency is everything. A design might look perfect on paper, but without clear workmanship standards and acceptance criteria, the final product can vary from build to build. That is exactly why IPC/WHMA-A-620 exists.

Overmolded cable assemblies are relied on in applications where failure is not an option. Industrial control panels, medical equipment, automotive sensors, laboratory instruments, and outdoor electronics all depend on strong strain relief, dependable sealing, and repeatable performance. Overmolding delivers that performance by encapsulating the connection point between the cable and its component interface, creating a unified structure that protects against moisture, vibration, abrasion, and general wear.

In product development, speed matters. Design teams are under constant pressure to move faster without increasing risk, especially when developing custom cable assemblies that require hard tooling and molded features.

In cable assembly manufacturing, overmolding is more than just a finishing touch; it is the process that protects internal wires, seals out moisture, and provides durability in tough environments. The quality of an overmolded cable assembly often determines how reliable the final product will be in the field. But one factor that is sometimes underestimated is how much temperature and humidity influence the overmolding process.

In the medical device industry, safety and reliability for electronics are non-negotiable. A single component failure can have serious consequences, which is why regulatory frameworks exist to set the bar for quality and consistency.

At the conclusion of our webinar, Understanding UL Wire Options that Surpass Industry Standards, we had several questions submitted to our presenter, User Interface & Cable Assembly Product Manager, Steven J. Goodman. We compiled these into a readable format on our blog.