FlawlessPerformance:Over50,000Glenair

OvermoldedCableAssembliesHaveBeen
InstalledinF16swithoutaSingleFailure

Overmolded Interconnect Cable Assemblies

for Aerospace Applications

Environmental/Mechanical Stress Factors in

Aerospace Interconnect Cables
High Performance Cable Assemblies
Must Be Able to Withstand Damage From:

Shock
Vibration
FluidImmersion
Abrasion
Clamping
Combustion
Corrosion

TemperatureCyclinginJetFuel
Altitude
Fungus
PressureExtremes
PullForces
Outgassing
Aging

The Advantages of Overmolding

Outstanding environmental protection for harsh and caustic environments
compared to braided or booted solutions
Viton,EPDM,ButylandGlenair
proprietarymaterialsproviderobust
protectionforconnectorsandcablesin
harsh/causticenvironments
Mechanicalperformanceisalsoenhanced
Injectionmolding/transfermoldingisa
simple,reasonablypricedsolutionto
physicalprotection
Designflexibility:fromsimplepointto
point,tocomplexmultiplebranch
assembliesevenfiberopticandhybrid
electrical/opticaldesigns

Typical Cable Construction

Connector Overmold Cross-Section

Overmolding as a Solution to Managing SinglePoint Ignition Sources in Aircraft Fuel Cells

Turnkey Solution to FAA SFAR-88 Requirements
Overmoldingeffectively
eliminatesallcableandwire
ignitionsources,includingarcing
andESD
Alsoimproveslongevityof
service
Reducedinstallationand
maintenancecost
Controlscorrosion/conductivity
problems
Improvesreliabilityandsafety

Overmolding as Solution to Cable

Routing and/or Weight Reduction
Efficiently Designed Multi-Branch Harnesses
Reduce Overall Weight and Package Space of Interconnect Cables

TurnkeysolutionswithGlenair
Connectors,Backshells,and
Assemblymaybeoptimizedfor
reducedweight

Routingperformanceenhanced
withrangeofstandardGlenair
toolingforallanglesand
junctions

History of Glenair Overmolded

Cables for Fuel-Cell Applications
F-16 Fighting Falcon
Modularconduitdesignsfailed
repeatedlyinF16andother
frontlinefighters.
Glenairintroducedunique
designtosolveleakage,
reliabilityandinstallation
requirements
Designincorporatednew
overmoldingmaterialsand
integralbulkheadfittings

Additional Military
Reference Applications
Proven Performance for Bell, Lockheed, Boeing and ETC
F18FuelCellAssembly
AdvancedF18E/FFuelCell
Assemblywithintegralfiberoptic
media
F22OvermoldedFuelCell
AssemblyandWheelWell
Assemblies
V22FuelCellAssembly
BombardierBulkheadFuelTank
ConnectorAssembly
C17OvermoldedConduitFuelCell
Assembly

Spotlight On Glenairs C-17

Overmolded Conduit Solution
New Glenair Design Met all Requirements and Significantly
Reduced Installation and Maintenance Costs

Sealedconduitsystem
withintegralclamp
mountings
Replacedrigidmetal
tubingsystemwith
significantinstallation
costsavings
Achievedallsafety,
reliability,andweight
objectives

C-17 Overmolded Conduit

Solution: Detailed View
New Glenair Design Met all Requirements and Significantly
Reduced Installation and Maintenance Costs

Cable Routing
and Packaging
An almostCapabilities
unlimited range of breakouts and layouts
Straight,90and45degreeangular
specifications.
Existingtoolingforallcommon
moldingadaptersandconnectors.
Breakout,bulkheadandtransition
toolingforallcommonconfigurations
Standardmoldingmaterialsas
wellasnewproprietaryformulasand
newmassproducedinjectionprocesses.
MoldedCableandConnectorIdentifiers

Production Packaging
Overmolding as a standard catalog offering
PointtoPointcordsets
availableforallSeries
80,Series22and
D38999fiberoptic
connectors
Standardizedpart
numberdevelopment
Acceleratedleadtimes

Additional Cable Shop Capabilities:

Custom Multi-Conductor Cables
For exacting operational and environmental conditions
Customelectrical,fiberopticandhybridconfigurations
Bulkcablesuppliedinshortonetimerunsaswellas
unlimitedquantitiesandlengths
Oneoftheindustrysbroadestselectionofbraided
shielding,coveringsandextrudedjacketing,including
NBC(nuclear,biological,chemical)materials
Cabledesignandengineeringsupportcoveringevery
EMI/EMP,mechanicalandenvironmental
designconsideration

Additional Cable Shop Capabilities:

Metal and Fabric Overbraiding
Durable lightweight cable assemblies
Flexible,andelasticoverbraiding
providesphysicalprotectionandEMI
Shielding
Extremetemperatureprotection:
from100oFto+500oF
Smoothesirregularshapes
andreducessnaggingin
lacing
tapeboundharnesses
Adds flexibility and repairability to
harness designs
Available in bulk or integrated into the
harness assembly service

Ultra-Lightweight Composite
RFI/EMI Braided Shielding
Nickel Plated Composite Shielding Offers Unique Solution to
Electromagnetic Compatibility

Expandable,flexible,high
strength,conductive,
elasticcompositematerial
Providesabrasion
resistanceandEMI
shieldingatafraction
of
theweightofmetalbraid

Application Development
The Bid Process
Assessmentofovermoldingworkisessentiallyabidprocess
andcostingexerciseasmostjobsaresubmittedwithcomplete
BOMSandassemblyschematics.
Newapplicationsareneverthelessevaluatedformechanical,
EMIandenvironmentalrequirements.
Glenairwilloftenaddvaluewithsuperiorknowledgeofwire
andcablelayoutandassembly,especiallyinprototypes.

Not Just Another Pretty Cable

The Ultimate Harsh Application Environment
HalliburtonsOilWellRecoveryand
RestorationDivisionemploysspecialized
trucksequippedwithseismicrecordersto
generateaccurateoilwellstatusdata.
Thefieldgeneratorswhichpowerthe
systemuseinterconnectcablingwhich
mustwithstandsevereweather,abusive
handlingandcausticchemicals.
Glenairovermoldedcableassemblies
provideflawless,durableserviceinthis
extremeenvironmentalapplication