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1. What Is Wire Harness Overmolding? Wire harness overmolding (also called connector overmolding, cable overmolding, or insert molding) is a manufacturing process in which a thermoplastic or thermoset resin is injection-molded directly over a pre-assembled wire harness, connector, or cable termination. The result is a seamless, integrated assembly where the plastic shell, wires, and connectors are permanently fused into a single, robust component. Unlike traditional connector housings that are mechanically crimped or snapped onto a wire, overmolding creates a chemically and mechanically bonded interface. This eliminates gaps, entry points for moisture, and mechanical stress concentrations — making it the method of choice for demanding environments in automotive, industrial, marine, and outdoor electronics applications.