You’re ready to finally order a custom cable assembly or wire harness of your own, but you need to know if extruded cables or cable molding is the better route. This debate in the world of custom cable manufacturers is nothing new. While both cable extrusion and wire molding have their benefits, choosing the right one for your project is a big deal.
Fortunately, we have you covered with all you need to know about your big decision. Our expert engineers unpack the values and unique features each option brings to the table so that you can make the best decision for your project. We’ll unpack the ins and outs of wire coating extrusion, molded cables, custom wire and cable components, and more. This is your guide to the age-old quandary — extruded cables versus cable molding for custom cable assemblies.
What Is Cable Molding?
Cable molding is a common practice among custom wire harness manufacturers. It encases a cable assembly in a layer of molded coating, typically made of a flexible material like plastic or rubber. This process protects connectors, wires, and other components from environmental hazards like moisture and dust.
This process involves developing a unique mold based on the custom cable assembly configuration. Once created, a liquid material is injected to coat the wires, connectors, and assembly elements entirely. As this liquid material hardens, it solidifies, forming a protective shield around each element and securing its position within the configuration.
In a custom cable assembly, cable molding can be an effective means of preventing disruption and protecting the delicate custom wire and cable elements within the assembly. Because of their protective qualities, molded cable assemblies are often used in heavy industrial settings where challenging environments and elements are commonplace. Think industrial manufacturing complexes, military applications, or medical facilities, and you’ll likely find a molded cable assembly nearby.
Despite its protective benefits, cable molding isn’t a one-size-fits-all wiring solution. Some situations require more flexibility for tight spaces, tricky connection points, or temperamental equipment. That’s why it’s essential to understand your connection needs and plan accordingly.
What Is Cable Extrusion?
As an alternate protective measure, many custom wire harness manufacturers provide extruded cables instead of molded cable assemblies. Cable extrusion involves coating individual wires and cables in a thin, flexible substance that insulates the wire from outside dangers. This process creates a uniform shield around the wire and conductors, ensuring consistent thickness, flexibility, and a smooth finish.
Wire extrusion is common in power cables, data cable assemblies, and other wire harnesses requiring additional flexibility and protection. Although not as rigid as a molded cable, an extruded cable assembly can benefit operational functionality and durability.
Extruded cables are generally more flexible and easier to manipulate than molded cable assemblies. This makes them invaluable for operational practicality and situations that demand malleable cables or adaptive connection solutions. You might find an extruded cable in telecommunications apparatuses, medical facilities, military applications, and aerospace engineering complexes.
Because of their adaptability, these cables offer many advantages for electronic equipment. This also makes them semi-portable for applications that require frequent relocation or on-the-road installation.
What Extruded Cables and Cable Molding Have in Common
At the core of each of these options lies the intention of protection. Extruded cables and cable molding offer additional protection for custom cable assemblies, supplying security and protection from physical dangers that may harm or damage the assembly’s interior components.
Despite using different methods, wire coating extrusion and cable molding are each designed to protect and defend. In this sense, they’re very similar. Their unique methodologies and differences, however, make them applicable to varying industries and connection needs.
In addition to their protective qualities, each measure offers supplemental durability to the custom cable assembly. Whether you’re coating the entire assembly in a hardening material or individually coating the wires and cables, these precautions increase the longevity of your cable assembly. Custom wires and cables, like dust and moisture, last longer when they encounter fewer hazards.
Cable molding and cable extrusion also have the ability to customize unique connection configurations. For situations requiring a unique solution, molded and extruded cable assemblies can help protect your one-of-a-kind connection assembly or wire harness.
What’s the Difference Between Extruded Cables and Molded Cables?
Although they have some similarities, the difference is that you need to make an extruded or molded cable right for your transference project. Let’s discuss some of the key differences and benefits in more detail.
Durability and Defense
Extruded Cables
While extruded cables offer additional protection, they are not as robust as the protection molded cables. However, the cable extrusion process provides a uniform, flexible coating that can be used in adaptive situations and environments. Although the coating on an extruded cable is not airtight, as with a molded cable, it still offers a layer around it, giving it some protection.
Exterior cables may not be best suited for environments where moisture and contaminants are consistently present. Extruded cables can be altered to offer adequate flexibility and durability for situations requiring enhanced resistance to chemicals, oils, or other hazards, improving adaptability to various conditions.
Molded Cables
The molding process provides exceptional protection against environmental factors like moisture, dust, kinks, and breakages. During the cable molding, each wire, connector, joint, and other elements are encased in a defensive coating, preventing anything from physically interfering with the inner components.
Because the inner elements are entirely coated, contaminants cannot enter or interact with the wires and internal components. This protection makes molded cable assemblies an excellent choice for outdoor environments, like watercraft, weather stations, renewable energy-generating facilities, and more.
Flexibility
Extruded Cables
Flexibility is the name of the game when using extruded cables. Because their coating creates uniform protection, extruded cables are often adaptable and flexible without the rigidity of molded cables. The extrusion process applies the insulating layer thinly and evenly around each custom wire and cable, making them light and pliable. This makes extruded cables ideally suited for tight spaces or applications requiring highly adaptive connection instruments.
Molded Cables
Due to the nature of cable molding, cables are often more rigid, leaving little to no wiggle room. These cables can often be bulkier due to the layer of protection and overall thickness of the gapless coating they receive. In situations that demand extra protection, this trade-off is well worth it to keep your cables securely in place and defend against environmental hazards.
Customization Capabilities
Extruded Cables
Extruded cables offer more flexibility in terms of material and makeup. The coating material can be chosen specifically for your equipment and environment. For example, you may want a higher resistance to chemicals if you work in a laboratory or chemical industrial plant. Extruded cables have a lot to offer when adapting to your specific needs. Plus, custom wire harness providers and custom cable manufacturers can adjust the length of your extruded cables to suit your unique connection situations, giving you that extra dose of customization.
Molded Cables
Molded cables are limited in customization simply because the mold must be designed for your specific apparatus. Not all cable manufacturers can accommodate every unique feature of your environment and transference needs, but an experienced custom wire harness provider, like Meridian Cable, can create a custom mold for just about any situation.
Cost Considerations
Extruded Cables
In general, extruded cables are less costly than molded cable assemblies simply because they are more flexible and less labor-intensive. Extruded cables can be produced in large quantities, making them more affordable and less time-consuming.
Molded Cables
Because of the process involved and the unique mold it requires, cable molding often comes with a slightly higher price tag than extruded cables. The added complexity of creating a unique mold and the extreme precision make a molded cable more labor-intensive, meaning it can take longer to produce, increasing the cost.
Which Cable Is Right for Me?
Several factors must be considered before choosing between an extruded cable and cable molding for your custom cable assembly.
Consider Cable Molding When:
- There are harsh working environments: If your cable will be exposed to harsh environments and relentless contaminants, you may want to consider a molded cable assembly for the best protective measures.
- You demand unyielding protection: If you’re dealing with sensitive equipment and protecting your power transmission or data is critical, a molded cable might be suitable.
- You don’t need flexibility: If adaptability is less important to you, a molded cable may be ideal.
Consider an Extruded Cable When:
- You’re operating in tight spaces: Consider an extruded cable if you require more flexibility and adaptability.
- Flexibility is most important to you: An extruded cable is the way to go when you need maximum adaptability.
- You’re ordering in high volumes: Because of its cost-effective and quick-turn manufacturing, extruded cables may be better for large orders and mass production.
Our team is here to help if you’re still in doubt. Our engineers can guide you through designing your custom cable assembly or wire harness to your exact specifications. Contact our team to start your project today.