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Low Pressure Molding (LPM) |
Injection Molding |
Potting |
Conformal Coating |
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Sealing prevents corrosion/fretting at contacts while maintaining stable geometry and insulation under temperature swings that otherwise cause resistance rise and signal issues. |
Gentle encapsulation protects contacts and terminations in simple connector designs, with minimal capability for thermal management or complex geometries. |
Generally unsuitable for encapsulating finished connectors, as pressure and flow can deform housings and disrupt contact alignment. |
Durable environmental protection, but bulk, weight, and lack of precision make it poorly suited for compact or high-density connector systems. |
Surface coating can reduce corrosion risk on exposed areas, but does not protect mating interfaces, provide sealing, or stabilize contact geometry. |
Simplified Connector Manufacturing
Connector and cable protection often gets solved with extra pieces: secondary boots, adhesives, add-on retention, and hardware that increases assembly time and variation. X2F enables integrated molded connector structures that build support, alignment, retention, and protection into the connector itself. This simplifies manufacturing while improving robustness at the transition.
Cable Transitions with Integrated Support
Cable transitions commonly require secondary boots, adhesives, or added parts to manage strain and sealing at the exit. X2F integrates mechanical support directly into the over molded transition, reducing dependence on secondary components while improving durability at a frequent failure point.
Alignment and Retention Designed In
Connector alignment issues are a common driver of rework, especially when alignment and retention are handled with secondary features added late in the build. X2F integrates alignment and retention features directly into molded connector structures and molded connector bodies. This reduces rework risk and simplifying assembly versus multi-part retention schemes.
Sealing Features Integrated into the Connector Structure
Sealed connectors can become multi-step assemblies when protection and sealing are achieved through separate parts and operations. X2F integrates protective features into molded connector structures to simplify sealing approaches and reduce assembly complexity.
Thermal-Aware Connector Packaging
Traditional power connector thermal handling often relies on added parts and conservative packaging. X2F enables more integrated connector structures that support thermal-aware designs, helping teams pursue higher performance packaging without adding unnecessary complexity.