Custom Overmolded Cable Assemblies – Trust Our Expertise

GCT Custom overmolded Cable Assemblies

Working with blue chip customers has developed GCT’s expertise in custom overmolded cable assemblies. GCT understand the complex nature of product development and have the skills and experience to help you design the perfect solution for your design, the starting point for considering a molded assembly is often a design challenge, GCT have helped many customers by working hand in hand on developing a custom solutions.

Overmolding provides an aesthetically pleasing and professional finish to your assemblies. In addition overmolding offers durability, improving the overall reliability of the cable assembly.

GCT also offer a range of standard connector overmolds, minor modifications such as strain reliefs, bushes, boots, grommets and PCB’s can be molded into your application for little cost.  Custom overmold tooling starts from as little as $500, making molded cables exception value.

If you seek a bespoke mating connector solution we can help, we’ve designed mating PCB connectors and overmolded cables for a variety of customers. For a flavor of our capability see our case studies.

All cables are fully tested and our production facilities are accredited to ISO9001:2008.  UL certification is available upon request.

Contact your local GCT office to discuss your requirements, we have expert staff to assist you in all locations, we support you wherever you design – wherever you manufacture.

Custom Connector Solutions

GCT has the design and engineering expertise to offer custom connector solutions.

Custom connector solutions

As an example of a recent design that was turned around in eight weeks, a customer approached GCT to provide an RJ45 modular jack with a very small width sidewalls, their application didn’t have the space to accept a standard size connector. After understanding the customers’ requirements and assessing the quality implications of molding very thin side walls, we asked ’why use sidewalls at all?’

GCT offered a modular jack connector without an outside wall, the key design challenge was to hold the eight contacts in place, as without a side wall they would be highly likely to move out of position upon mating. GCT proposed a snap fit comb to be fitted over the contacts of the SMT connector post reflow soldering. The fitted comb not only keeps the contacts in the correct position for the lifetime of the product but also holds the contacts upright for final assembly, securely fastened in place by the customer’s SFP die-cast hood.

To allow auto SMT assembly the main body of the connector was designed to be fitted on the underside of a cutout PCB with two locating pegs providing placement assistance and extra strength.

GCT also offered custom tape & reel packing, no special film was required as flat area was designed on the connector to allow vacuum suction, commercially GCT delivered the solution for the same price as a standard SMT mod jack.

What’s more GCT is also providing the mating special cable assembly, screened to prevent EMI/RFI and including a special offset keyed RJ45 cable plug, which removes any chance of mismating.

“Here at GCT we are very confident in our abilities to exceed customer expectations when it comes to the design and build of innovative connector solutions” stated Steve Turner, Engineering Director of GCT. “What’s more, our engineers relish the challenge of not only designing something that is technically sound, but also that the design is commercially viable”.

Contact your local GCT office to discuss your custom connector requirements.

See Custom connector solutions at the GCT website.