Medical devices must perform reliably in environments where cleanliness, safety and durability are essential. Cables usually need to be repeatedly handled, flexed, cleaned and exposed to demanding sterilisation processes.
At Novara Technologies, we use medical cable overmoulding to create robust, application-specific interconnect solutions that withstand these challenges while delivering dependable performance.
What does cable overmoulding involve?
Overmoulding involves placing a cable, connector or electronic component into a specially designed mould and applying a protective material around it. This forms a strong, integrated enclosure that can help protect vulnerable connection points from mechanical stress and environmental exposure.
Unlike separate housings or covers, the moulded material becomes an integral part of the finished assembly. Our overmoulded cable assemblies can be customised using materials such as PVC, polypropylene, polyethylene, polyurethane and thermoplastic elastomers, depending on the requirements of the application.
Improving protection against everyday stresses
Medical cables can experience frequent bending, pulling and movement during routine use. These forces are often concentrated where the cable meets its connector, creating a potential point of failure.
Overmoulding allows us to incorporate carefully designed strain relief, reducing stress at this critical interface and helping to prevent damage to the conductor. The resulting assembly means it’s also more resistant to shock, vibration, abrasion and premature ageing.
By producing bespoke overmoulded medical cable assemblies, we can tailor the cable construction, connector protection and ergonomics to the intended device. This is particularly important for equipment that must remain reliable throughout repeated clinical use.
Supporting cleanliness and environmental protection
Fluid and dust ingress can affect the reliability of electrical connections and embedded components. Overmoulding creates a close-fitting protective barrier, helping to seal sensitive areas and reduce the risk of contamination or moisture reaching them.
Material selection is equally important. Medical cable materials may need to be suitable for human interaction while also tolerating demanding cleaning or sterilisation methods. Our custom Cable Assemblies can be designed around these requirements, including the use of medical-grade polymers certified to relevant USP Class VI or ISO 10993 standards where specified.
Protecting intelligent electronics
Modern medical devices increasingly combine cables with sensors, identification technology and other electronic components. These intelligent functions require effective protection without adding unnecessary bulk.
We have extensive experience integrating electronics into cable assemblies. Our injection moulding, encapsulation and low-pressure overmoulding capabilities can protect printed circuit boards and other delicate components against fluids, dust and harsh operating conditions. Low-pressure processing also reduces the risk of component displacement during moulding.
Medical cable expertise from prototype to production
At Novara Technologies, we manufacture custom cables from initial prototype through to full production. Our overmoulded medical cable assemblies are produced in our bespoke cleanroom under an ISO 13485 quality management system, with injection moulding equipment designed for overmoulding medical connectors.
We support customers with the design of cables, creating drawings, introducing new products and project management. By considering materials, strain relief, sealing, ergonomics and manufacturability from the outset, we help create durable assemblies that meet demanding medical device requirements.
If you are developing a new medical cable or upgrading an existing design, speak to us about a bespoke overmoulding solution.