When it comes to waterproof cable assemblies, the type of material is just as important as the design itself. The wrong insulation, jacket or overmoulding can lead to water or other liquids or materials entering. It can also lead to a poor performance overall, with components needing to be replaced prematurely.
At Novara Technologies, we understand that selecting the right materials is essential for producing waterproof cable assemblies that perform consistently, last longer, and meet rigorous quality standards.
Here’s a breakdown of the top materials, and why they matter.
1. Thermoplastic Elastomers (TPE): Flexible and Reliable
TPE is a go-to material for overmoulding due to its excellent flexibility, impact resistance, and watertight sealing capability. TPE combines the processing advantages of plastics with the elasticity of rubber, making it ideal for protecting against water ingress, dust, and mechanical strain.
We frequently use TPE for waterproof cable assemblies where dynamic movement or bending is expected, especially in industrial automation, automotive wiring, and consumer electronics.
2. Polyurethane (PU): High Abrasion and Chemical Resistance
PU offers outstanding resistance to wear and tear and exposure to chemicals. Because it’s so tough, it’s ideal for harsh industrial and outdoor environments, especially where cables may be exposed to oil, fuel, or repeated flexing.
PU is often chosen for waterproof cable assemblies used in robotics, agricultural machinery, and other demanding applications where durability is critical.
3. Polyvinyl Chloride (PVC): Cost-Effective and Versatile
PVC remains one of the most commonly used materials in cable manufacturing. It offers good electrical insulation, flame retardancy, and water resistance — all at a competitive cost.
While not suitable for extreme temperatures or high-flex environments, PVC is a dependable choice for general-purpose waterproof cable assemblies in consumer and commercial products. It can also easily be customised in terms of colour and finish.
4. Polypropylene (PP) – Lightweight and Chemically Inert
PP is valued for its low density and excellent resistance to acids, bases, and moisture. It is commonly used in cable jackets and layers of insulation where low weight and chemical stability are required.
In applications such as medical equipment, waterproof cable assemblies made with PP provide a strong balance of protection and less weight. .
5. Silicone: for Extreme Temperatures and Medical-Grade Use
Silicone is ideal for high-temperature or low-temperature environments, withstanding conditions from -60°C to over 200°C. Its flexibility remains stable even under thermal cycling, making it suitable for medical and aerospace applications.
In addition, silicone is biocompatible, making it an excellent material for waterproof cable assemblies used in medical devices and surgical instruments. At Novara, we use medical-grade silicone to ensure compliance with stringent hygiene and sterilisation standards.
6. Fluoropolymers (FEP, PTFE, ETFE) – Maximum Chemical and Heat Resistance
These high-performance polymers offer unparalleled chemical resistance, thermal stability, and electrical insulation. They’re ideal for use in hazardous environments or where cables are exposed to corrosive substances and high voltages.
Finding Your Ideal Solution
Every application demands a different combination of properties, from flexibility and abrasion resistance to flame resistance and biocompatibility. That’s why Novara Technologies works closely with clients to specify and source the ideal materials for every project.
Whether your project requires moulded strain reliefs, UV resistance, integrated logos, or resistance to salt spray, we’ll recommend a material that ensures long-lasting, high-performance cable assemblies.
Looking for a reliable partner to develop your next waterproof cable assembly? Contact Novara Technologies for more information.