Category: Blog

Xact EMS delivers tailored solutions to meet the precise needs of manufacturers, offering custom converting services using advanced equipment and deep application expertise. Whether it’s die-cutting, laminating, slitting, or kiss-cutting, we specialize in transforming high-performance materials into ready-to-use, application-specific components that enhance product reliability, efficiency, and performance.

From material selection to custom conversion, we’re your trusted source for engineered materials solutions—delivering precision, performance, and speed to every project.

THERM-A-GAP PAD 60

THERM-A-GAP PAD 60 Thermally Conductive Gap Filler Pads
Products	Material Thickness	Carrier Type	Shape	Size
61-04-1015-PAD60	0.04 in (1.01 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-04-CUSTOM-PAD60	0.04 in (1.01 mm)	No Carrier (Unsupported)	Custom	Custom
61-05-1015-PAD60	0.05 in (1.27 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-05-CUSTOM-PAD60	0.05 in (1.27 mm)	No Carrier (Unsupported)	Custom	Custom
61-06-1015-PAD60	0.06 in (1.52 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-06-CUSTOM-PAD60	0.06 in (1.52 mm)	No Carrier (Unsupported)	Custom	Custom
61-07-1015-PAD60	0.07 in (1.78 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-07-CUSTOM-PAD60	0.07 in (1.78 mm)	No Carrier (Unsupported)	Custom	Custom
61-08-1015-PAD60	0.08 in (2.03 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-08-CUSTOM-PAD60	0.08 in (2.03 mm)	No Carrier (Unsupported)	Custom	Custom
61-09-1015-PAD60	0.09 in (2.29 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-09-CUSTOM-PAD60	0.09 in (2.29 mm)	No Carrier (Unsupported)	Custom	Custom
61-10-1015-PAD60	0.10 in (2.54 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-10-CUSTOM-PAD60	0.10 in (2.54 mm)	No Carrier (Unsupported)	Custom	Custom
61-11-1015-PAD60	0.11 in (2.79 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-11-CUSTOM-PAD60	0.11 in (2.79 mm)	No Carrier (Unsupported)	Custom	Custom
61-12-1015-PAD60	0.12 in (3.05 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-12-CUSTOM-PAD60	0.12 in (3.05 mm)	No Carrier (Unsupported)	Custom	Custom
61-13-1015-PAD60	0.13 in (3.30 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-13-CUSTOM-PAD60	0.13 in (3.30 mm)	No Carrier (Unsupported)	Custom	Custom
61-14-1015-PAD60	0.14 in (3.56 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-14-CUSTOM-PAD60	0.14 in (3.56 mm)	No Carrier (Unsupported)	Custom	Custom
61-15-1015-PAD60	0.15 in (3.81 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-15-CUSTOM-PAD60	0.15 in (3.81 mm)	No Carrier (Unsupported)	Custom	Custom
61-16-1015-PAD60	0.16 in (4.06 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-16-CUSTOM-PAD60	0.16 in (4.06 mm)	No Carrier (Unsupported)	Custom	Custom
61-17-1015-PAD60	0.17 in (4.32 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-17-CUSTOM-PAD60	0.17 in (4.32 mm)	No Carrier (Unsupported)	Custom	Custom
61-18-1015-PAD60	0.18 in (4.57 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-18-CUSTOM-PAD60	0.18 in (4.57 mm)	No Carrier (Unsupported)	Custom	Custom
61-19-1015-PAD60	0.19 in (4.83 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-19-CUSTOM-PAD60	0.19 in (4.83 mm)	No Carrier (Unsupported)	Custom	Custom
61-20-1015-PAD60	0.20 in (5.08 mm)	No Carrier (Unsupported)	Flat sheets	10 in x 15 in (254 mm x 381 mm)
61-20-CUSTOM-PAD60	0.20 in (5.08 mm)	No Carrier (Unsupported)	Custom	Custom
62-02-1015-PAD60A	0.02 in (0.508 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-03-1015-PAD60A	0.03 in (0.762 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-04-1015-PAD60A	0.04 in (1.01 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-04-CUSTOM-PAD60A	0.04 in (1.01 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-05-1015-PAD60A	0.05 in (1.27 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-05-CUSTOM-PAD60A	0.05 in (1.27 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-06-1015-PAD60A	0.06 in (1.52 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-06-CUSTOM-PAD60A	0.06 in (1.52 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-07-1015-PAD60A	0.07 in (1.78 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-07-CUSTOM-PAD60A	0.07 in (1.78 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-08-1015-PAD60A	0.08 in (2.03 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-08-CUSTOM-PAD60A	0.08 in (2.03 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-09-1015-PAD60A	0.09 in (2.29 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-09-CUSTOM-PAD60A	0.09 in (2.29 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-10-1015-PAD60A	0.10 in (2.54 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-10-CUSTOM-PAD60A	0.10 in (2.54 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-11-1015-PAD60A	0.11 in (2.79 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-11-CUSTOM-PAD60A	0.11 in (2.79 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-12-1015-PAD60A	0.12 in (3.05 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-12-CUSTOM-PAD60A	0.12 in (3.05 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-13-1015-PAD60A	0.13 in (3.30 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-13-CUSTOM-PAD60A	0.13 in (3.30 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-14-1015-PAD60A	0.14 in (3.56 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-14-CUSTOM-PAD60A	0.14 in (3.56 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-15-1015-PAD60A	0.15 in (3.81 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-15-CUSTOM-PAD60A	0.15 in (3.81 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-16-1015-PAD60A	0.16 in (4.06 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-16-CUSTOM-PAD60A	0.16 in (4.06 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-17-1015-PAD60A	0.17 in (4.32 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-17-CUSTOM-PAD60A	0.17 in (4.32 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-18-1015-PAD60A	0.18 in (4.57 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-18-CUSTOM-PAD60A	0.18 in (4.57 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-19-1015-PAD60A	0.19 in (4.83 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-19-CUSTOM-PAD60A	0.19 in (4.83 mm)	A – Aluminum Foil with PSA	Custom	Custom
62-20-1015-PAD60A	0.20 in (5.08 mm)	A – Aluminum Foil with PSA	Flat sheets	10 in x 15 in (254 mm x 381 mm)
62-20-CUSTOM-PAD60A	0.20 in (5.08 mm)	A – Aluminum Foil with PSA	Custom	Custom

THERM-A-GAP 579

In military operations, performance and reliability are non-negotiable — no matter the environment. Xact EMS, an AS9100-certified and CMMC Level 2-compliant manufacturer, delivers custom overmolded military connectors engineered for the toughest mission-critical applications.

Our overmolded connector solutions are built to withstand extreme conditions, offering exceptional environmental sealing that protects against water, chemicals, dust, and temperature extremes. Advanced EMI shielding ensures secure and interference-free communication, even in high-risk battlefield and aerospace environments.

Military-Grade Connectors We Commonly Support:

• MIL-DTL-38999 – High-performance circular connectors featuring robust EMI shielding for aerospace, communications, and ground systems.
• MIL-DTL-5015 – Ruggedized power and signal connectors ideal for military vehicles, weapons systems, and ground support equipment.
• MIL-DTL-26482 – Compact, bayonet-style connectors optimized for avionics, ground vehicles, and tactical communication systems.
• MIL-DTL-83513 (Micro-D) – Miniature high-density connectors used in UAVs, handheld devices, and compact military electronics.
• MIL-DTL-24308 (D-Sub) – Reliable data and signal connectors utilized in military control panels, computers, and interface systems.
• MIL-DTL-83723 – Hybrid circular connectors designed to perform in high-vibration, high-temperature environments such as aircraft and combat vehicles.
• ARINC 600 & 404 – Modular aerospace-grade connectors for advanced military avionics and navigation systems.
• VG95234 – Reverse bayonet connectors commonly deployed in military communication and field equipment.

Built for Mission-Critical Applications:

From ground control stations to unmanned aerial systems (UAS) and defense communication platforms, Xact EMS’s overmolded connectors deliver superior mechanical strength, EMI protection, and long-term durability. Our solutions are tailored to meet the demands of combat-ready environments where failure is not an option.

Common Applications:

• Tactical radio and communication systems
• Satellite uplink and downlink terminals
• UAV and drone avionics
• GPS navigation and positioning systems
• Defense-grade power and signal distribution networks

When your mission demands rugged, reliable connectivity, Xact EMS is your trusted partner for precision-engineered, overmolded military connector assemblies.

Overmolding strengthens circular connectors by reducing mechanical strain at the cable-to-connector junction. This improves strain relief, minimizes cable fatigue, and extends the lifespan of connectors in high-flex, high-vibration environments.

Precision-Engineered Overmolded Solutions

XACT specializes in custom overmolded Amphenol circular connectors, built to withstand the harshest conditions in military, industrial, aerospace, and transportation applications.

Amphenol Circular Connector Series

• 62GB – Compact, multi-contact connectors with bayonet coupling for secure AC/DC connections.
• 62IN Series – Environmental-resistant connectors with three-point bayonet coupling, ideal for military and industrial use.
• 97B Reverse Bayonet – MIL-DTL-5015 compliant connectors with quick-lock bayonet coupling, designed for high-shock and vibration environments.
• Amphe-Ex – Explosion-proof connectors engineered for hazardous environments, compatible with copper, coaxial, and fiber optics.
• Amphe-GTR – High-power, IP67-rated connectors utilizing RADSOK® technology, supporting up to 120A.
• Amphe-HST – Heat shrink tubing solutions resistant to chemicals and solvents, available in various shrink ratios.
• Amphe-Lite – Composite-bodied connectors based on 38999 Series III, designed for harsh environments.
• Amphe-PD™ – Touch-proof, rectangular high-power connectors featuring a secure push-pull coupling.
• Amphe-Phase – High-current, single-pin connectors with IP2X finger-proof protection and bayonet locking.
• ARC Series™ – Environmentally sealed, rectangular connectors for high-density pin configurations.
• ATHD Series™ – Heavy-duty, single-pole power connectors with IP67/69K sealing and secure latching.
• AUTOMATE Mini-FAKRA – Compact, high-performance automotive interconnects for next-generation vehicle systems.
• Cable Joiner & FICX – Quick-install cable joiners for versatile wire sizes and applications.
• Ceres – Waterproof circular connectors available in multiple sizes for enhanced environmental protection.
• CMB – MIL-DTL-26482 Series 1 compliant metal bayonet connectors for power and signal transmission.
• Coaxial Inserts – Size 8 coaxial inserts designed for DIN and D-Sub applications.
• CONEC IP67 Power Bayonet – Industrial-grade connectors with bayonet locking for secure, high-strength connections.
• CONEC M12x1 Bayonet Quick Locking – Quick-locking M12 connectors for efficient and reliable installation.
• CONEC M12x1 X-Coding – High-speed data connectors optimized for industrial networking applications.
• DHR Downhole Rotatable – High-temperature, rotatable connectors built for harsh downhole environments.

Custom Overmolded Connector Solutions by XACT

At XACT, we design and manufacture custom overmolded circular connectors tailored to the unique needs of high-performance industries. Our solutions enhance durability, reliability, and longevity, making us a trusted provider for mission-critical applications.

Industries & Applications

Our overmolded Amphenol connectors provide rugged, high-performance connectivity for a wide range of industries, including:

• Robotics – Reliable interconnects for automation, motion control, and autonomous systems.
• Marine Electronics – Sealed, corrosion-resistant connectors for shipboard power and communication systems.
• Telecommunications – High-speed, EMI-shielded connectors for secure networking infrastructure.
• Railway Systems – Ruggedized connectors for onboard electronics, signaling, and trackside communication.
• Industrial Machinery – Durable interconnects for manufacturing equipment, automation, and heavy machinery.

Why Choose XACT??

With a focus on engineering excellence and application-specific solutions, XACT delivers battle-tested, industry-proven overmolded connectors that ensure secure, uninterrupted performance in extreme conditions.

Ruggedized M12 Connectors for Demanding Environments

Xact introduces an enhanced-survivability ruggedized solution for M12 connectors, designed to exceed industry standards while maintaining full compliance with IEC 61076-2-101. Built for reliability in harsh conditions, these connectors are available in multiple configurations:

• A-Code: Male and female with 4, 5, and 8 contact arrangements
• D-Code: Male and female with 4-contact arrangements

Engineered for Durability and Performance

Xact’s ruggedized M12 connectors integrate a stainless-steel sleeved plastic contact carrier and a stainless-steel collar, ensuring superior mechanical protection. Additionally, the fully overmolded design provides IP67/IP68 waterproofing when mated, making them ideal for field automation applications.

Key Benefits

• Reliable operation in extreme temperatures (-40°C to +90°C)
• Fully overmolded for enhanced durability
• Waterproof and resistant to harsh environmental conditions

Applications

Designed for mission-critical applications where durability and reliability are paramount, Xact’s M12 connectors are well-suited for:

• High-risk environments
• Oceanographic research and monitoring
• Hydraulic fracturing and mining
• Land-based oilfield operations

Xact’s ruggedized M12 connectors offer unmatched performance in the toughest conditions, ensuring seamless connectivity when it matters most.

XACT EMS, with locations in Houston, Calgary, and Markham, is a vertically integrated manufacturer of cable and cable assemblies for demanding industries such as Oil & Gas, Mining, Defense, Instrumentation, Rail, Marine, and Transportation. With over 25 years of dedicated experience in providing ruggedized solutions, XACT EMS is recognized as a leader in its field. Leveraging a wide range of components, materials, and advanced manufacturing capabilities, XACT EMS delivers solutions designed for the harshest and most critical environments.

From electrical and environmental performance to flex-life and durability, XACT EMS engineers application-specific cable and assembly solutions tailored to industry needs. Our expertise in rapid prototyping, fast turnaround, and seamless scaling from prototype to full production ensures reduced time-to-market and optimized performance for every project.

At XACT Engineered Manufacturing Services, we understand that the oilfield presents unique challenges that demand reliable and robust cable solutions. With our state-of-the-art manufacturing facilities in Houston and Calgary, we are dedicated to serving the oil and gas industry with high-quality custom cable assemblies specifically designed for the rigors of the field.

 

Tailored Solutions for the Oilfield

Our expertise in custom cable assembly enables us to create solutions that meet the stringent requirements of oilfield applications. Whether it’s harsh weather conditions, exposure to corrosive elements, or the need for enhanced durability, our cables are engineered to perform. Here’s how we do it:

1. Specialized Design: We leverage advanced 3D modeling and injection molding techniques to design cable assemblies that withstand extreme conditions. Our in-house engineering team collaborates closely with clients to ensure that every assembly is tailored to specific application needs.
2. Ruggedized Components: Our custom cables feature ruggedized designs that include environmental sealing for moisture resistance and protection against abrasion. This ensures longevity and reliability in demanding oilfield environments, from drilling rigs to offshore platforms.
3. Compliance and Quality: Our manufacturing processes adhere to rigorous standards, including MIL-Spec and ISO 9001 certifications. This commitment to quality assurance means you can trust that our cable assemblies will meet the highest industry benchmarks.
4. Rapid Prototyping and Production: With our agile manufacturing capabilities, we offer quick turnaround times without sacrificing quality. Our facilities in Houston and Calgary are equipped to handle varying order sizes, providing flexibility for your projects with no minimum order quantities (MOQ).

 

 

Local Expertise, Global Reach

Having operations in both Houston and Calgary allows us to effectively serve our clients across North America. Our Houston facility is strategically positioned to cater to the vibrant oil and gas industry in the Gulf Coast region, while our Calgary location is well-equipped to support clients in the Canadian oilfields.

We take pride in our commitment to the oilfield sector, recognizing the critical role that reliable cable assemblies play in ensuring operational success. By choosing XACT, you gain a partner who understands the complexities of the oil and gas industry and is dedicated to delivering solutions that keep your operations running smoothly.

 

Join Us on the Journey

As we continue to grow and innovate, XACT Engineered Manufacturing Services remains steadfast in our commitment to the oilfield. Our focus on quality, performance, and customer satisfaction ensures that we are not just a supplier, but a valued partner in your operations.

Contact us today to learn more about our custom cable solutions for the oilfield and discover how we can help you meet your project requirements. Experience the difference with XACT—where excellence is built into every connection!

 

More Information

XACT Engineered Manufacturing Services is North America’s premier provider of high-reliability custom cable assemblies for ruggedized applications in defense, aerospace, oil and gas, mining, transportation, industrial automation, and harsh environment electronics. We specialize in engineered interconnect solutions designed to maintain signal integrity and power delivery under extreme conditions.

Our capabilities encompass advanced cable design, 3D CAD modeling, electromechanical simulation software, and rapid prototyping, and additive manufacturing (3D printing). We conduct thorough RF (VSWR) performance analysis, mechanical stress testing, and environmental validation testing, ensuring compliance with military-grade specifications and industry standards such as IPC/WHMA-A-620, J-STD-001, AS9100D, ISO 9001:2015, and NIST 800-171.

We excel in manufacturing overmolded and non-overmolded cable assemblies with complex connector geometries including circular, rectangular, and custom-shaped overmolds. Our solutions feature environmental sealing (IP-rated), electromagnetic interference (EMI) and radio frequency interference (RFI) shielding, and breakout configurations from 2 to 15 legs.

With expertise in meeting the most stringent specifications, we provide military and aerospace-grade cordsets and are known for our high performance in the harshest conditions such as the oilfield and mines. Our in-house machining capabilities allow for the design and production of custom injection molds, ensuring rapid prototyping and production and the ability to perform rubber molding such as Viton, EPDM, and Neoprene.

We are committed to lean manufacturing principles, offering turnkey solutions with quick turnaround times, no minimum order quantity (MOQ), and robust rework and repair services. For reliable, mission-critical cable assemblies, XACT EMS delivers precision-engineered solutions that support the most demanding operational environments.

When it comes to finding a reliable partner for your custom cable assembly needs, look no further than XACT Engineered Manufacturing Services. As North America’s leading manufacturer of custom cable assemblies, we pride ourselves on delivering high-quality solutions tailored to the unique requirements of various industries, including military, oil and gas, mining, transportation, and industrial automation.

Why Choose XACT for Your Custom Cable Assemblies?

1. Expertise and Experience: With over 20 years of industry experience, our team has developed deep knowledge in cable design, materials selection, and manufacturing processes. We understand the intricacies of creating durable, high-performance cable assemblies that stand up to the toughest conditions.
2. Custom Solutions: At XACT, we specialize in custom wiring harnesses and cable assemblies designed to meet your specific application requirements. Whether you need complex geometries or unique configurations, our in-house 3D modeling and injection molding capabilities allow us to create tailored solutions that fit your needs.
3. Rapid Turnaround: We understand that time is of the essence in manufacturing. Our agile processes ensure quick order processing and delivery without compromising quality. Plus, we offer no minimum order quantities (MOQ), making it easy for you to scale your orders according to your project demands.
4. Quality Assurance: Quality is integral to our manufacturing process. We adhere to stringent standards such as IPC-620, J-STD-001, AS9100D, and ISO 9001. Our commitment to continuous improvement and rigorous testing ensures that every cable assembly we produce meets the highest quality benchmarks.
5. Comprehensive Capabilities: From environmental sealing and EMI/RFI shielding to breakout configurations and electromechanical assembly, XACT offers a wide range of services and solutions. Our team collaborates closely with you to design and build custom molds and components that enhance your product’s performance and reliability.
6. End-to-End Support: Our commitment to our customers goes beyond manufacturing. We provide support throughout the entire process, from concept to completion. Our team is dedicated to ensuring your satisfaction and success with every project.

Partner with XACT for Your Custom Cable Assembly Needs

Choosing the right manufacturer for your custom cable assemblies is crucial for the success of your projects. At XACT Engineered Manufacturing Services, we are committed to providing you with innovative, reliable, and high-performance solutions that meet the unique challenges of your industry.

Ready to take your projects to the next level? Contact us today to learn more about our custom cable assembly services and how we can help you achieve your goals. Experience the XACT difference—where quality, performance, and customer satisfaction come first!

More Information

XACT Engineered Manufacturing Services is North America’s premier provider of high-reliability custom cable assemblies for ruggedized applications in defense, aerospace, oil and gas, mining, transportation, industrial automation, and harsh environment electronics. We specialize in engineered interconnect solutions designed to maintain signal integrity and power delivery under extreme conditions.

Our capabilities encompass advanced cable design, 3D CAD modeling, electromechanical simulation software, and rapid prototyping, and additive manufacturing (3D printing). We conduct thorough RF (VSWR) performance analysis, mechanical stress testing, and environmental validation testing, ensuring compliance with military-grade specifications and industry standards such as IPC/WHMA-A-620, J-STD-001, AS9100D, ISO 9001:2015, and NIST 800-171.

We excel in manufacturing overmolded and non-overmolded cable assemblies with complex connector geometries including circular, rectangular, and custom-shaped overmolds. Our solutions feature environmental sealing (IP-rated), electromagnetic interference (EMI) and radio frequency interference (RFI) shielding, and breakout configurations from 2 to 15 legs.

With expertise in meeting the most stringent specifications, we provide military and aerospace-grade cordsets and are known for our high performance in the harshest conditions such as the oilfield and mines. Our in-house machining capabilities allow for the design and production of custom injection molds, ensuring rapid prototyping and production and the ability to perform rubber molding such as Viton, EPDM, and Neoprene.

We are committed to lean manufacturing principles, offering turnkey solutions with quick turnaround times, no minimum order quantity (MOQ), and robust rework and repair services. For reliable, mission-critical cable assemblies, XACT EMS delivers precision-engineered solutions that support the most demanding operational environments.

At XACT EMS, we specialize in providing premium overmolding services that are built to withstand the toughest environments, particularly for frac trucks in the oil industry. With over 20 years of experience across industries, our expertise in design, materials selection, and injection molding allows us to deliver unmatched reliability.

🔧 Why Overmolding?

• Enhanced product durability & longevity
• Strain & stress relief for wire terminations
• Waterproof protection
• Custom cable exit angles for better integration

🔩 XACT EMS Advantage:

• 15 overmolding machines across two North American locations
• Custom dies manufactured in-house
• Agile processes for rapid turnaround
• Guaranteed quality & on-time delivery

Whether you need ruggedized cables for energy, defense, mining, or transportation, our turnkey solutions ensure you get the performance and reliability you need to power your operations.

💼 Ready to get started? Request a quote today and discover why XACT EMS is the trusted partner for overmolded cable solutions.

#OvermoldedCables #FracTrucks #OilIndustry #CustomCables #XACTEMS #ManufacturingExcellence #TurnkeySolutions

XACT Engineered Manufacturing Services is North America’s premier provider of high-reliability custom cable assemblies for ruggedized applications in defense, aerospace, oil and gas, mining, transportation, industrial automation, and harsh environment electronics. We specialize in engineered interconnect solutions designed to maintain signal integrity and power delivery under extreme conditions.

Our capabilities encompass advanced cable design, 3D CAD modeling, electromechanical simulation software, and rapid prototyping, and additive manufacturing (3D printing). We conduct thorough RF (VSWR) performance analysis, mechanical stress testing, and environmental validation testing, ensuring compliance with military-grade specifications and industry standards such as IPC/WHMA-A-620, J-STD-001, AS9100D, ISO 9001:2015, and NIST 800-171.

We excel in manufacturing overmolded and non-overmolded cable assemblies with complex connector geometries including circular, rectangular, and custom-shaped overmolds. Our solutions feature environmental sealing (IP-rated), electromagnetic interference (EMI) and radio frequency interference (RFI) shielding, and breakout configurations from 2 to 15 legs.

With expertise in meeting the most stringent specifications, we provide military and aerospace-grade cordsets and are known for our high performance in the harshest conditions such as the oilfield and mines. Our in-house machining capabilities allow for the design and production of custom injection molds, ensuring rapid prototyping and production and the ability to perform rubber molding such as Viton, EPDM, and Neoprene.

We are committed to lean manufacturing principles, offering turnkey solutions with quick turnaround times, no minimum order quantity (MOQ), and robust rework and repair services. For reliable, mission-critical cable assemblies, XACT EMS delivers precision-engineered solutions that support the most demanding operational environments.

At XACT Engineered Manufacturing Services, we pride ourselves on being a leader in overmolded cable assemblies tailored for rugged environments. Our expertise in custom wiring harnesses and custom cable assemblies sets us apart in industries such as military, oil and gas, mining, and transportation.

🔧 Why Choose Our Overmolded Solutions?

We leverage advanced injection molding techniques to deliver high-reliability custom assemblies that ensure signal integrity and durability in the harshest conditions. Our commitment to quality and precision enables us to provide:

• Complex geometries for enhanced functionality and integration
• Environmental sealing (IP-rated) designs that withstand moisture and contaminants
• EMI/RFI shielding for superior performance in electrically noisy environments

With over 20 years of experience, our skilled team utilizes 3D CAD modeling and electromechanical simulation software to create engineered interconnect solutions that meet stringent specifications. We offer rapid prototyping, ensuring that your custom solutions are ready when you need them — no minimum order quantities required!

🔍 Capabilities at a Glance:

• Custom wiring harnesses and assemblies tailored to your specifications
• Advanced injection molding for molded and non-molded cable assemblies
• Compliance with industry standards such as MIL-Spec, IPC/WHMA-A-620, and ISO 9001
• Comprehensive testing including RF (VSWR) analysis, mechanical stress testing, and environmental validation

Whether you need a custom assembly for a military application or a ruggedized solution for the oil and gas industry, XACT EMS is here to deliver unparalleled performance and reliability.

🚀 Ready to enhance your connections? Partner with XACT EMS for your next project and experience the difference in quality and service!

#OvermoldedCableAssemblies #CustomWiringHarness #InjectionMolding #CustomAssembly #WiringHarness #XACTEMS #ManufacturingExcellence

XACT Engineered Manufacturing Services is North America’s premier provider of high-reliability custom cable assemblies for ruggedized applications in defense, aerospace, oil and gas, mining, transportation, industrial automation, and harsh environment electronics. We specialize in engineered interconnect solutions designed to maintain signal integrity and power delivery under extreme conditions.

Our capabilities encompass advanced cable design, 3D CAD modeling, electromechanical simulation software, and rapid prototyping, and additive manufacturing (3D printing). We conduct thorough RF (VSWR) performance analysis, mechanical stress testing, and environmental validation testing, ensuring compliance with military-grade specifications and industry standards such as IPC/WHMA-A-620, J-STD-001, AS9100D, ISO 9001:2015, and NIST 800-171.

We excel in manufacturing overmolded and non-overmolded cable assemblies with complex connector geometries including circular, rectangular, and custom-shaped overmolds. Our solutions feature environmental sealing (IP-rated), electromagnetic interference (EMI) and radio frequency interference (RFI) shielding, and breakout configurations from 2 to 15 legs.

With expertise in meeting the most stringent specifications, we provide military and aerospace-grade cordsets and are known for our high performance in the harshest conditions such as the oilfield and mines. Our in-house machining capabilities allow for the design and production of custom injection molds, ensuring rapid prototyping and production and the ability to perform rubber molding such as Viton, EPDM, and Neoprene. 

We are committed to lean manufacturing principles, offering turnkey solutions with quick turnaround times, no minimum order quantity (MOQ), and robust rework and repair services. For reliable, mission-critical cable assemblies, XACT EMS delivers precision-engineered solutions that support the most demanding operational environments. 

In today’s demanding environments, from military operations to industrial applications, the reliability of electronic connections is paramount. Overmolding has emerged as a critical manufacturing process for enhancing the durability and performance of cable assemblies and connectors used in ruggedized electronics.

What is Overmolding?

Overmolding is a manufacturing technique that involves applying a second layer of material over an existing component, typically using injection molding. This process provides several advantages, particularly for applications in harsh environments where protection from physical, chemical, and environmental factors is essential.

Key Benefits of Overmolding in Ruggedized Electronics

1. Enhanced Durability: Overmolding creates a robust barrier against mechanical stress, abrasion, and impact, making it ideal for applications where cables and connectors are subject to rigorous use.
2. Environmental Sealing: By incorporating overmolding, manufacturers can achieve higher IP ratings, offering excellent resistance to moisture, dust, and other contaminants. This is particularly vital for military and outdoor applications where exposure to the elements is a constant challenge.
3. EMI/RFI Shielding: Overmolded components can be designed to provide effective electromagnetic interference (EMI) and radio frequency interference (RFI) shielding. This capability is crucial for maintaining signal integrity in sensitive electronic systems.
4. Strain Relief: The overmolding process offers strain relief for wire terminations, reducing the likelihood of fatigue failure at connection points. This feature extends the lifespan of the assemblies, which is critical for mission-critical operations.
5. Custom Design Flexibility: With in-house capabilities for 3D modeling and custom mold design, manufacturers can create unique configurations that meet specific requirements. This customization ensures that the assemblies are tailored to the unique demands of each application.

Applications in Ruggedized Electronics

Overmolding is increasingly being adopted in various sectors, including:

• Military and Aerospace: Custom cable assemblies designed to meet stringent MIL-Spec standards, providing the necessary durability and performance under extreme conditions.
• Oil and Gas: Ruggedized connectors and cables that can withstand harsh environments and maintain operational reliability in drilling and exploration activities.
• Mining: Overmolded solutions that protect electronic components from abrasive materials and high-stress conditions encountered in mining operations.
• Transportation: Custom wiring harnesses designed to ensure reliable connections in vehicles operating in demanding conditions, including extreme temperatures and vibration.

Conclusion

As the demand for reliable and robust electronic connections continues to grow, overmolding stands out as an essential process in the manufacturing of ruggedized electronics. At XACT Engineered Manufacturing Services, we are committed to leveraging our advanced injection molding capabilities to deliver high-performance, custom overmolded cable assemblies that meet the rigorous standards of various industries.

If you’re looking to enhance the durability and reliability of your electronic systems, consider the advantages of overmolding. Our expertise in this field ensures that you receive solutions tailored to your unique needs, ensuring the success of your projects in even the most challenging environments.

Contact us today to learn more about our overmolding capabilities and how we can support your ruggedized electronics needs!

More Information:

XACT Engineered Manufacturing Services is North America’s premier provider of high-reliability custom cable assemblies for ruggedized applications in defense, aerospace, oil and gas, mining, transportation, industrial automation, and harsh environment electronics. We specialize in engineered interconnect solutions designed to maintain signal integrity and power delivery under extreme conditions.

Our capabilities encompass advanced cable design, 3D CAD modeling, electromechanical simulation software, and rapid prototyping, and additive manufacturing (3D printing). We conduct thorough RF (VSWR) performance analysis, mechanical stress testing, and environmental validation testing, ensuring compliance with military-grade specifications and industry standards such as IPC/WHMA-A-620, J-STD-001, AS9100D, ISO 9001:2015, and NIST 800-171.

We excel in manufacturing overmolded and non-overmolded cable assemblies with complex connector geometries including circular, rectangular, and custom-shaped overmolds. Our solutions feature environmental sealing (IP-rated), electromagnetic interference (EMI) and radio frequency interference (RFI) shielding, and breakout configurations from 2 to 15 legs.

With expertise in meeting the most stringent specifications, we provide military and aerospace-grade cordsets and are known for our high performance in the harshest conditions such as the oilfield and mines. Our in-house machining capabilities allow for the design and production of custom injection molds, ensuring rapid prototyping and production and the ability to perform rubber molding such as Viton, EPDM, and Neoprene.

We are committed to lean manufacturing principles, offering turnkey solutions with quick turnaround times, no minimum order quantity (MOQ), and robust rework and repair services. For reliable, mission-critical cable assemblies, XACT EMS delivers precision-engineered solutions that support the most demanding operational environments.

When it comes to custom cable and harness prototypes for the most demanding environments, Xact EMS stands out as Canada’s trusted source. With over 25 years of experience serving industries such as oil and gas, military, mining, transportation, robotics, and more, we specialize in designing and producing ruggedized cable assemblies that meet the highest standards of durability and performance.

Our facilities in Calgary and Houston offer a complete range of services, from prototype development to first article and in-house quality testing. With no minimum order quantities (MOQ) and a reputation for delivering reliable solutions in the harshest conditions, Xact EMS is your partner for custom cable assemblies.

25 Years of Building for Rugged Environments

Xact EMS has a proven track record of supplying custom wiring harnesses and cable assemblies for verticals that require extreme reliability. Our expertise includes:

• Oil and Gas: From offshore drilling to downhole operations, our cables are built to withstand the most punishing conditions.
• Military: We understand the exacting standards for military-grade cable assemblies, providing solutions that ensure mission-critical reliability.
• Mining: In the depths of underground operations, our ruggedized cables endure intense pressure, vibration, and abrasion.
• Transportation: We build robust wiring systems for heavy vehicles, rail, and aerospace, where performance and safety are paramount.
• Robotics and Automation: For applications where precision and flexibility are key, our cables are designed to support seamless operation in industrial and hazardous settings.

Custom Prototyping with No MOQ

We recognize the need for flexibility in prototype development. Whether you require a single prototype or multiple units for testing, Xact EMS delivers custom cable assemblies without being bound by large minimum order quantities. This flexibility is critical in fast-moving industries where design adjustments and iterations are common.

In-House First Article Production and Testing

At our Calgary and Houston facilities, we offer full in-house services to streamline the prototype process. From the initial concept to the production of your first article, we ensure that every cable assembly is tailored to meet your exact requirements. This includes thorough inspections and testing to confirm compliance with design specifications, performance standards, and industry regulations.

Our in-house quality testing capabilities allow us to verify the electrical, mechanical, and environmental properties of each custom cable prototype. By controlling the entire process from design to testing, we reduce lead times, improve quality control, and enhance overall reliability.

Designed for Harsh Environments

The industries we serve require cables that can survive and perform in the most unforgiving conditions. From extreme temperatures and high pressures to exposure to chemicals and rough handling, Xact EMS’s ruggedized cables are engineered to deliver:

• Durability: Designed to resist wear and tear, extending the lifespan of your equipment.
• Reliability: Tested to perform consistently, even in the harshest field environments.
• Safety: Built to meet or exceed industry standards, ensuring safe operation in critical applications.

Benefits for Engineers and Designers

Working with Xact EMS offers several key advantages for electromechanical engineers, electrical engineers, and cable and harness designers in Canada:

• Rapid prototyping: Our end-to-end in-house services help accelerate your development timelines.
• No MOQ: Prototype exactly what you need, without the pressure of large order requirements.
• Comprehensive testing: We ensure your prototypes are tested to perform in extreme environments.
• Decades of expertise: Leverage our 25 years of experience to create reliable, ruggedized solutions for your specific application.

Conclusion

As Canada’s source for custom cable and harness prototypes, Xact EMS brings 25 years of experience to industries that demand durability, performance, and safety. Our flexible approach, no MOQ requirements, and in-house testing capabilities ensure that you get exactly what you need—fast and with the reliability you expect.

Whether you’re working in oil and gas, military, mining, or other ruggedized sectors, trust Xact EMS to deliver prototypes built for the toughest conditions.