EN
EN

Custom molded cables designed for your application

At Mekoprint, we specialize in molded cables and molded cable assemblies engineered to meet the standards of durability, resistance, and reliability.

 

Whether you’re sourcing for industrial automation, medical devices, or harsh outdoor environments, our custom molded cables deliver the protection and performance your application demands over time.

Why choose molded cable assemblies?

For engineers and strategic sourcing specialists, the decision to choose molded cable assemblies often comes down to one thing: performance under pressure. Our custom molded cable assemblies are designed with that in mind, combining materials, design, and process control to deliver consistent quality in even the toughest conditions.

 

Key advantages:

 

  • Improved protection: The overmold acts as a barrier against dust, water, and chemical ingress.
  • Enhanced durability: Engineered to endure repetitive motion, strain, and exposure to mechanical stress.
  • Seamless integration: Compact, space-saving designs improve form factor and reduce assembly time.
  • Long-term reliability: Withstands extreme temperatures and corrosive environments to maximize uptime.

Click to download our cables lookbook 

Custom molded cables tailored to your application

No two projects are the same. That’s why we offer custom molded cables and assemblies fully tailored to your requirements - from connector type to cable routing and overmold geometry. Whether you need a high-flex cable for robotics or a sealed power connection for outdoor use, our engineering team collaborates closely with yours to develop the optimal solution.

 

Options in customized molded cables include sizes, colors, materials, connectors, fillers, insulation, and shields.

 

Our development process begins with your application requirements. We consider environmental conditions, electrical specifications, space constraints, and cost parameters to deliver customized molded cable solutions that meet exact standards.

Overmolding technologies: Low-pressure & High-pressure injection molding

Mekoprint offers two main overmolding processes for molded cable assemblies, each with its own benefits depending on your needs. Low-pressure injection moulding and high-pressure injection moulding are two manufacturing processes used for different applications and materials.

 

Both methods produce molded cables assemblies with excellent protection and tight dimensional tolerances, ensuring consistent reliability in high-performance applications. The choice of technology depend on needed properties in the final product.

 

Low-pressure injection moulding is suited for encapsulating electronics with thermoplastic polyamide materials at lower pressures and temperatures, while high-pressure injection molding is ideal for forming thermoset materials into complex shapes with high strength and precision.

Stig Bergendorff
Sales director, Cables
+45 2234 5005
sbe@mekoprint.com

Get in touch with us

Low-Pressure Injection Molding

Low-pressure injection molding is ideal for small-scale and sensitive electronics. It uses polyamide material injected at low pressure and temperature to encapsulate components without causing damage.

 

The process is efficient, cost-effective, and well-suited for prototypes and mid-volume production of custom molded cables - especially when sealing connectors or delicate circuitry.

.

Materials

 

The primary material used is Technomelt (previously known as Macromelt), a thermoplastic polyamide that’s sustainable, cost-efficient, and environmentally friendly. Made from 80% renewable raw materials, it provides excellent electrical insulation and chemical stability.

 

Technomelt complies with UL, RoHS, and REACH standards, making it a reliable choice for high-performance cable assemblies.

Process

 

Low-pressure molding works at pressures under 100 psi and temperatures between 170°C and 240°C, reducing the risk of damaging sensitive electronics. It allows for the creation of custom-shaped overmolds, connector sealing, and functional reliefs.

 

The use of aluminum tooling further reduces costs and speeds up production. This method is also ideal for achieving IP-rated sealing and integrating molded cables into complex assemblies.

Download free lookbook

Get an overview of cables and wire harness solutions, manufacturing process, customer collaborations, and much more.

High-pressure injection molding

High-pressure injection molding is the preferred method for applications requiring strong mechanical performance and robust environmental sealing.

 

This process uses thermoplastic materials injected at high pressure to form molded cable assemblies with excellent resistance to impact, chemicals, and temperature fluctuations. It’s ideal for mass production and for cable assemblies operating in harsh environments where long-term durability is essential.

.

Materials

 

A wide range of thermoset materials can be used, including TPE, TPU, and PVC compounds—each selected for their specific mechanical and chemical properties. Reinforced options like PBT with fiberglass, ABS, or PVC enhance strength, flexibility, and heat resistance.

 

Material choice is guided by your specific requirements for temperature range, adhesion, elasticity, and even color to ensure optimal performance and compatibility.

Process

 

High-pressure molding excels at producing complex, detailed shapes while fully encapsulating connectors and electronic components. The high pressure and temperature allow for tight dimensional control, precision features, and high-quality surface finishes. It creates a reliable seal against water, dust, moisture, and heat, contributing to overall product longevity and performance.

 

The use of this process also reduces the need for post-processing, thanks to the smooth finish and consistent texture of molded parts—improving both efficiency and the appearance of the final assembly.

Application areas for molded cables

Our molded cables are used in a wide range of industries where failure is not an option:

 

  • Industrial Automation: High-flex, shielded assemblies for sensors, actuators, and robotics.

  • Telecom & Data: Reliable connections for outdoor and high-speed communication systems.

  • Defense & Aerospace: Engineered for mission-critical systems where rugged reliability matters.

  • Green Tech: Weatherproof solutions for EV charging and renewable energy installations.

 

No matter your industry, we can deliver molded solutions that perform.

Materials that stand up to the environment

The material choice is key to any molded cable project. We offer a wide range of materials designed to resist oil, chemicals, UV radiation, and extreme temperatures. Depending on your application, we may use:

 

  • Polyurethane for flexibility and abrasion resistance

  • Polyamide for rigidity and chemical protection

  • TPE/TPU for environmental sealing and flame resistance

  • Silicone for high-heat and biocompatibility requirements

 

Each overmold is selected based on your performance criteria.

Scalable production and fast turnaround

Whether you're developing a custom harness for a new prototype or ramping up to full-scale production, Mekoprint is equipped to deliver. Our flexible manufacturing setup supports low-volume custom runs as well as high-volume serial production - all with consistent quality.

 

Thanks to our molding lines and in-house tooling, we can quickly pivot from concept to production. And because we control the full value chain - from connector sourcing to overmolding - you benefit from reliable lead times and competitive pricing.

Compliance and traceability

All molded cable assemblies are manufactured in ISO 9001-certified facilities, with traceability and documentation that meet global standards. We can also comply with specific regulatory or industry requirements, such as RoHS, REACH, or compliance with other certifications.

Let’s build your custom molded cable assemblies

At Mekoprint, we’re not just another supplier - we’re your engineering partner. From initial concept to mass production, we work with you to develop customized, high-performance molded cable solutions that meet your technical, commercial, and operational goals.

 

Whether you're looking for rugged assemblies that thrive in harsh environments, or flexible connections built for repeated use, we’ve got the experience and expertise to make it happen.

 

Ready to start your project? Let’s connect and build a solution that works.

Stig Bergendorff
Sales director, Cables
+45 2234 5005
sbe@mekoprint.com

Get in touch with us

Related solutions
Solutions