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Insert versus molded grommets for an Automotive Cable Harness

Insert versus molded grommets for an Automotive Cable Harness

Insert versus molded grommets for an Automotive Cable Harness

During some recent competitor sample evaluation we've noticed our competitors are overmoulding grommets and fastners onto the wire harness of a sensor. We did some investigation inhouse regarding the cost benefit of inserting the grommet (using a waffle machine) vs overmolding the grommet/fasteners. Our determination was that inserting the grommet was still the most cost effective. The basis we used for the calculation was three seperate overmold stations. I am just wondering if we missed a trick here? Is it possible to use a shuttle table to synchronouosly mold three to four components onto the harness at once? Typically these harnesses are up to 1.5M long....we had thought about a system where the cable could be feed off a roll, pulled into the mold press, overmolded with components and then cut to length. Is this a dream or is there equipment on the market that can handle this type of operation? In the end I am wondering if people can give some feedback on why overmolded grommets/fastners are being used. The benefits for positioning, quality of seal and retention are clear but does it justify the cost?.....and yes this is a high volume production scenario.

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