Overmolding
Process.

Why this is relevant — Overmolding cells share the rapid prototyping tooling discipline this energy case addressed.

A US energy management company needed initial physical samples to validate a complex custom overmolded power cable design before committing to production tooling.

Challenge

Standard production molds for overmolded cable assemblies are costly and time-consuming, creating a barrier for early-stage NPI validation requiring only a handful of units.

Solution

Proposed a rapid prototyping approach using silicone molds instead of hard tooling, allocating 50 pieces of raw material to produce an initial batch of 5 sample units for testing.

Result

Delivered functional samples within a 3-4 week turnaround (including 2 weeks for silicone mold creation), enabling the customer to proceed with physical testing and design iteration without upfront hard tooling investment.

Why this is relevant — Overmolding cells share the ul certification compliance tooling discipline this energy case addressed.

A US smart energy OEM required a custom power cable assembly with strict safety certifications for home electrification applications.

Challenge

The 2AWG 3-conductor cable had diameter and flexibility issues, and an initial proposed material substitution (flame retardant tape for the inner jacket) was rejected by the customer because it failed to meet the mandatory TYPE TC-ER certification requirement for both inner and outer jackets.

Solution

Collaborated directly with the raw cable manufacturer to engineer a compliant inner and outer jacket material combination that met the TYPE TC-ER standard while achieving the target diameter and flexibility specs.

Result

Successfully provided a compliant technical specification that satisfied the customer's mechanical engineering team and maintained the project's trajectory toward high-volume production.