Flawless Performance: Over 50,000 Glenair
Overmolded Cable Assemblies Have Been
Installed in F-16s without a Single Failure
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:
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Shock
Vibration
Fluid Immersion
Abrasion
Clamping
Combustion
Corrosion
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Temperature Cycling in Jet Fuel
Altitude
Fungus
Pressure Extremes
Pull Forces
Outgassing
Aging
The Advantages of Overmolding
Outstanding environmental protection for harsh and caustic environments
compared to braided or booted solutions
 Viton, EPDM, Butyl and Glenair
proprietary materials provide robust
protection for connectors and cables in
harsh/caustic environments
 Mechanical performance is also enhanced
 Injection molding/transfer molding is a
simple, reasonably priced solution to
physical protection
 Design flexibility: from simple point to
point, to complex multiple branch
assemblies—even fiber-optic and hybrid
electrical/optical designs
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
 Overmolding effectively
eliminates all cable and wire
ignition sources, including arcing
and ESD
 Also improves longevity of
service
 Reduced installation and
maintenance cost
 Controls corrosion/conductivity
problems
 Improves reliability and safety
Overmolding as Solution to Cable
Routing and/or Weight Reduction
Efficiently Designed Multi-Branch Harnesses
Reduce Overall Weight and Package Space of Interconnect Cables
 Turnkey solutions with Glenair
Connectors, Backshells, and
Assembly may be optimized for
reduced weight
 Routing performance enhanced
with range of standard Glenair
tooling for all angles and
junctions
History of Glenair Overmolded
Cables for Fuel-Cell Applications
F-16 Fighting Falcon
 Modular conduit designs failed
repeatedly in F-16 and other
front-line fighters.
 Glenair introduced unique
design to solve leakage,
reliability and installation
requirements
 Design incorporated new
overmolding materials and
integral bulkhead fittings
Additional Military
Reference Applications
Proven Performance for Bell, Lockheed, Boeing and ETC
 F-18 Fuel-Cell Assembly
 Advanced F-18 E/F Fuel Cell
Assembly with integral fiber optic
media
 F-22 Overmolded Fuel Cell
Assembly and Wheel Well
Assemblies
 V-22 Fuel Cell Assembly
 Bombardier Bulkhead Fuel-Tank
Connector Assembly
 C-17 Overmolded Conduit Fuel Cell
Assembly
Spotlight On Glenair’s C-17
Overmolded Conduit Solution
New Glenair Design Met all Requirements and Significantly
Reduced Installation and Maintenance Costs
 Sealed conduit system
with integral clamp
mountings
 Replaced rigid metal
tubing system with
significant installation
cost savings
 Achieved all safety,
reliability, and weight
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 Capabilities
An almost unlimited range of breakouts and layouts
 Straight, 90 and 45 degree angular
specifications.
 Existing tooling for all common
molding adapters and connectors.
 Breakout, bulkhead and transition
tooling for all common configurations
 Standard molding materials as
well as new proprietary formulas and
new mass-produced injection processes.
 Molded Cable and Connector Identifiers
Production Packaging
Overmolding as a standard catalog offering
 Point-to-Point cordsets
available for all Series
80, Series 22 and
D38999 fiber optic
connectors
 Standardized part
number development
 Accelerated lead times
Additional Cable Shop Capabilities:
Custom Multi-Conductor Cables
For exacting operational and environmental conditions
 Custom electrical, fiber optic and hybrid configurations
 Bulk cable supplied in short one-time runs as well as
unlimited quantities and lengths
 One of the industry’s broadest selection of braided
shielding, coverings and extruded jacketing, including
NBC (nuclear, biological, chemical) materials
 Cable design and engineering support covering every
EMI/EMP, mechanical and environmental
design consideration
Additional Cable Shop Capabilities:
Metal and Fabric Overbraiding
Durable lightweight cable assemblies
 Flexible, and elastic overbraiding provides
physical protection and EMI Shielding
 Extreme temperature protection:
from -100oF to +500oF
 Smoothes irregular shapes
and reduces snagging in
lacing- tape bound harnesses
 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, highstrength, conductive,
elastic composite material
 Provides abrasion
resistance and EMI
shielding at a fraction
of the weight of metal
braid
Application Development
The Bid Process
 Assessment of overmolding work is essentially a bid process
and costing exercise as most jobs are submitted with complete
BOMS and assembly schematics.
 New applications are nevertheless evaluated for mechanical,
EMI and environmental requirements.
 Glenair will often add value with superior knowledge of wire
and cable layout and assembly, especially in prototypes.
Not Just Another Pretty Cable
The Ultimate Harsh Application Environment
 Halliburton’s Oil Well Recovery and
Restoration Division employs specialized
trucks equipped with seismic recorders to
generate accurate oil well status data.
 The field generators which power the
system use interconnect cabling which
must withstand severe weather, abusive
handling and caustic chemicals.
 Glenair overmolded cable assemblies
provide flawless, durable service in this
extreme environmental application