Electrical Wire & Cable Crimping: Benefits & Methods

Electrical Wire & Cable Crimping: Benefits & Methods

Understanding the Go-To Joining Method for Electrical Cable & Wires   Secure, reliable connections are vital to the performance of cables, wires, cable assemblies, and wire harnesses prevalent in electrical and telecommunications systems. Crimping and...

Wire & Cable Conductors: Purpose, Materials, & Coatings

Wire & Cable Conductors: Purpose, Materials, & Coatings

Understanding Common Conductor Types for Wires & Cables   At the center of each electrical wire, and each individual wire within a cable, is a conductor which is the electrical highway for carrying power or data from one point to another. Conductors are...

Not only is CAI capable of manufacturing wire harnesses, but they can provide specialty injection molding and overmolding processes to ensure your wires and wire harness assemblies are robust, well secured, and protected by various forms.


Simply stated, injection molding is the process of injecting melted plastic resins into a mold. Once the plastic sets-up, becoming firm, the mold opens and the parts are released.

Injection molding is a specialty process CAI provides for a variety of applications. We enjoy being able to supply our customers with not only assembled products, but with assemblies and products that are rugged and protected for their applications and environments.


We offer a variety of resins, each with their own impressive qualities and benefits, for your customized project. A few examples of the premium materials we provide are Polyethylene (PE) — a budget-friendly choice that is chemical resistance , Acrylic (PMMA) — which is cost-effective as well as a good alternative to glass and Urethane (TPU) — which has rubber-like elasticity and high temperature properties.

A full, extensive list of our injection moldings resins can be found here.



We provide injection molding for many parts within the specialty automotive industry. For example, we provide injection molding for the plastic frame on switch panels within vehicles. Also, we provide molding for the back mounted parts for hearses and limos.

Our molding can be found where frequent connections/disconnections occur, and also where your applications require protection from hazards (heat, water, chemical, abrasion, etc.). Our overmolding process is individually customized to provide even the most high tech overmolding solutions.

For example, we can infuse resins with glass nylon fibers to make them stronger, and offer mold flow analysis to ensure the molding process of your molded component produces the necessary durability and looks aesthetically pleasing.


Wherever there is a need for a rugged, secure connection within the commercial and residential spheres, you can be certain to see CAI’s injection molding applicability. It is important to have secure overmolding where there is frequent plugging & unplugging of cords and connections, especially if they are exposed to the harsher environment.

Furthermore, if you look closely at your hair dryer, curling iron, electric razor plugs, apple charger cord, USB connector, Airpod case, etc, you will see examples of injection molding and why it is important in a residential space. The molding provides peace of mind because it provides safer homes for both you and your children. CAI can provide you with custom injection molding or overmolding for your applications, no matter the size or geometry.

CAI offers specialty finishes and can overmold different materials, such as plastic plated knobs on appliances. We can add weight to a molded knob, add a chrome finish and match it to the rest mating parts of an appliance. This way, the knobs on the stove look cohesive and do not retain the heat of a similar metal knob.


The aerospace industry has injection molding throughout design applications. The knobs within the plane cockpits are often injection molded and overmolded. In these examples, knobs are molded with various colors and can be specialty decorated with translucent dimensions that allow light to pass through. When the knobs are turned, the indicators and directionals light up. This with specialty overmolding of threaded inserts or encoders adds to the functionality.

With CAI’s specialty injection molding process, your wire components, harnesses, and housings will be built to withstand environmental hazards and operate at peak efficiency with unmatchable aesthetic options. As always, we stand behind our products, providing cost-effective solutions that surpass expectations.


Since 1986, CAI has delivered custom, high-quality components and wire harness manufacturing to customers across the globe. Offering a personalized approach to every project, CAI partners with customers to create innovative products that exceed industry standards.

We creating niche product prototypes or helping a customer turn their idea into a full production run. CAI’s turnkey manufacturing approach delivers a complete product from design to delivery.

Contact us for more information on why our wire harnessing process is the best fit for your project. Visit the wire harnessing page on our website or reach out to our team to start work on your custom project.