2-Shot Overmolded PCBA (Bottom)
Cavist created the 2-Shot Overmold for electronics that require additional chemical resistance, along with superior abrasion and wear capability. This demo USB overmold shows the most basic approach. The premold safely encapsulates the PCBA with hot melt, while the second shot of TPE is strong, durable and easily color compounded. This bottom view demonstrates a […]
2-Shot Overmolded PCBA (Top)
Cavist created the 2-Shot Overmold for electronics that require additional chemical resistance, along with superior abrasion and wear capability. This demo USB overmold shows the most basic approach. The premold safely encapsulates the PCBA with hot melt, while the second shot of TPE is strong, durable and easily color compounded. This top view demonstrates a custom […]
Overmold for Wearable LEO Electronics
A leading manufacturer of wearable law enforcement equipment partnered with Cavist to create a 2-Shot Overmold solution for a point-of-view camera system for Law Enforcement Officers (LEO). The design challenges were immense, but Cavist was able to come up with a solution to move the product from prototyping and into high-volume production.
Overmolded Stacked PCBA and Display
A fully encapsulated PCB, with sensitive SMT components, requires a unique molding approach. This stacked PCB assembly required two molding steps to safely overmold the display and the electronics. Minimizing trapped air and vacuum voids is an important consideration.
Sealed 90 degree Connector
This design allows the cable to exit 90 degrees away from the connector axis. This yields a low profile design that offers plenty of strain relief and good adhesion.
Overmolded Smart Connector
This smart connector has a PCBA inline with a cable exiting the overmold. We mold this product in two steps: first in semi-transparent amber to form the light pipe, and secondly in opaque black. The result is a completely sealed cable and connector assembly with a functioning LED indicator light.
Mil-Spec Round Connector Overmold
This custom connector required a rugged design for a defense application. Low pressure molding material safely encapsulates the conductors and seals the back side of the connector. Proper adhesion and a good strain relief design are very important for large diameter cable assemblies.
Overmolded Automotive ECU
A superior product requires a superior solution. That is what we came up with for this high-volume automotive application. A sealed connector interface with mechanical interlock that will prevent delamination at both the connector body and the PCB periphery.
Overmolded USB Devices
Overmolding allows these USB devices, with LEDs and Light Pipes, to be protected with an IP67 rating. This means they could survive being immersed in water, at a depth of up to 1 meter, for 30 minutes!
Sealed DB Connector with Ribbon Cable
Smart cables, or smart connectors, are an excellent fit for overmolding. The inline PCB is concealed and protected within the molding material, while there are sealed shutoffs around both the connector and the ribbon cable.