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By - Karishma Katrat

How Injection Moulding Process forms an Integral Part of Katlax Connectors’ Manufacturing ?

The injection moulding process begins with raw plastic resin, known as thermoplastic, being dumped into a hopper. This resin is then heated typically to between 300° – 650° F where it melts and is injected into a steel mould.

These moulds contain cavities that have been carefully manufactured to meet the specific designs of the desired product. The melted thermoplastic fills the cavity and quickly cools and hardens to create a finished product.

What is Overmolding?

Overmolding is a type of injection moulding process that combines multiple materials into a singular part or product. Overmolding can be used to combine similar materials of a different colour, or to combine materials for functional purposes, such as giving a product a soft grip.


  1. Better adhesion between components
  2. More compact design
  3. Lower labour costs during production
  4. Noise and vibration reduction
  5. Protection from UV and corrosive chemicals
  6. Waterproofing
  7. Electrical insulation

However, these advantages come with a cost. They require a more complex and expensive setup process for manufacturing. With that said, overmolding is often reserved for specialty parts and high-volume production.

What is the Difference Between Insert Moulding and Overmolding?

Insert moulding is when plastic is injected into a mould with a pre-placed insert. This insert helps shape the part. Insert moulding is very similar to standard injection moulding; the only difference is the pre-placed insert inside of the mould. This insert can be made of metal or various types of plastic. Overmolding, on the other hand, is when a singular part or product is made by combining two or more materials.

Cable Overmolding and Assembly

Cable overmolding is a manufacturing process that combines and seals a wire with a connector resulting in a single unified part. The added strength, quality, and protection overmolding provides makes it an ideal method of cable production across all industries.​

The injection moulding process is a key factor in cable overmolding as it allows the machinery to accurately control the critical tolerances to the external temperature and pressure. Continuously controlled hot melt thermoplastic is used for overmolding to provide a consistent design and to maintain the right balance between rigidity and flexing of the cable and the cable housing. ​

During the manufacturing process, the material is moulded over the cable/wires while the cable is being inserted into an insulated or non-insulated raceway or connector.


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