Custom Cable Assemblies

Epoxy Backshells

An epoxy backshell is made by using epoxy at the termination exit (area where wires exit) of a connector and typically starts at the end of the shell and extends a short distance. Epoxy backshells are commonly used for solder-cup connections to protect the solder joints and provide strain relief on the wires. Epoxy backshells can also be an appropriate solution for crimped contacts. Although crimped contacts are already protected within the shell of the connector body, epoxy backshells can be used as an efficient method to provide additional strain-relief and a secure termination for braiding. Braiding is encapsulated within the epoxy back shell and mechanically secures the braid to the connector. Ulti-Mate has different manufacturing processes that are suited for different quantities and can support our customers with non-standard options and designs.

Overmolding

When additional strain relief or grip is required, overmolding could be a suitable solution. In overmolding, pelletized plastics are fed through an overmold press, which heats/compresses the pellets into a liquid. The liquid plastic is then flowed into a mold that allows the plastic to form into a specific shape. Typically, overmolds start at the termination end of a connector and extends over the wires. Ulti-Mate has helped multiple customers by developing concepts into fully modeled designs. Ulti-Mate’s in-house overmold presses can use materials such as polyurethane, PVC, polypropylene, santoprene, and others.

For circular connectors, overmolding can help provide grip and orientation. Having markings on the overmold can indicate the north position to users so that keyed mating orientation is readily apparent. The shape of the overmold can also help prevent snagging, which is a critical concern in applications such as operating room equipment.

Overbraiding

Ulti-Mate Connector can use off-the-shelf expandable braids for custom cable assemblies. These off-the-shelf solutions are pre-woven and must be larger than the cable assembly wire bundle in order to slide the braid over the wires. This leads to braids that are typically loose fitting. When using metal braiding, EMI is usually the concern and having loosely fitted metal braiding allows for EMI emission/ingression as the braid bunches and separates in normal use. The solution to these concerns is to braid directly onto the cable assembly which will provide a tight fit over the wires.

Our 16 and 24 bobbin machines are capable of providing metal and fabric braiding to simple and complex branch assemblies. The most common fabric material, Nomex, provides excellent abrasion and environmental protection. Metal braiding is typically a 36 AWG copper alloy and is primarily used for EMI protection. Metal braiding can also be used to form cable assemblies into a particular shape. In such instances, Ulti-Mate can pre-form assemblies, test fit using custom fixtures, and package in special packaging to ensure that installation is smooth and free from potential issues. Our 16 and 24 bobbin machines are capable of providing metal and fabric braiding to simple and complex branch assemblies. The most common fabric material, Nomex, provides excellent abrasion and environmental protection. Metal braiding is typically a 36 AWG copper alloy and is primarily used for EMI protection. Metal braiding can also be used to form cable assemblies into a particular shape. In such instances, Ulti-Mate can pre-form assemblies, test fit using custom fixtures, and package in special packaging to ensure that installation is smooth and free from potential issues.

Using Ulti-Mate to overbraid provides a much tighter fit that is made specifically for each assembly. Concerns with snagging and EMI are minimized and routing cables through tight dimensional constraints becomes easier.

Complex Harnesses

Many simple designs use a double-ended assembly with wires from one end terminating at the other end. However, some designs can save weight and space by using multi-branched cable assemblies. Ulti-Mate has the design and manufacturing expertise to help our customers meet the tightest space constraints. Using build fixtures and go/no-go fixtures, Ulti-Mate can ensure cable assemblies will fit as designed into our customers’ systems.

Flex Assemblies

When space is so constrained that even wires will not fit, flex board assemblies can help customers route complex twists and sharp turns using a fraction of the space. Flex assemblies have many design considerations and requires close collaboration with our customers to produce the best design for manufacturability and installation.

Collaboration

Ulti-Mate collaborates closely with our customers to understand their requirements on a deep level. After collecting all the information, Ulti-Mate can provide a design that customers can test within their models before spending time and capital on prototype samples.