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Custom Molded Cable and Overmolded Cable Assemblies

Cord Master manufactures custom molded cables to your exacting specifications. 

Molded and overmolded cable assemblies provide extra protection and strain relief to cables. This ensures that the interface between the cable and backshell of the connector are not damaged. Overmolded cable assemblies are higher quality and last longer than standard cables.

Cord Master Engineering utilizes custom resins such as engineering thermoplastics, low smoke zero halogen (LSZH) and thermoset resins. 


Assembly Overmold Design

Cord Master builds custom cables, connectors, and backshells for military and industrial applications.

Custom Molds for Industry-Specific Markets

We build single or double ended, “Y” assemblies, straight and right angle overmolding, cable jacketing and European style connectors.

Molds for Unique Cable Assembly Designs

Cord Master Engineering engineers custom molded strain-relief, hybrid and multi-legged cables.

Custom Tooled Mold Casts:

We can design in logos, letters, numbers, designators and names.

Molding vs. Overmolding

Custom over-molding services are when we apply polymers to a mil spec (military specification) connector. The polymer provides a coating over the connector and bonds the connector to the cable jacketing.


Custom molding services are when the molded polymers provides the structure for the individual conductors. A typical male or female connection you find at the end of an extension cord would be an example of a custom molding operation.


Any molding on cords is called “insert injection molding” because unlike a fully closed mold, the injection molds used to work on cords have to allow the cord or cable to stick out of the mold.

Our on-site molding enables rapid prototyping, fast lead times and competitive costs for high quality products.
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