When deciding on a power cord, common considerations include plug and connector styles, cord length, and voltage. However, another important factor is determining whether you need a molded or a mechanical power cord. Here, we discuss the differences between these types of power cords, their benefits, and how to choose the best style for your needs.
Molded Power Cords vs Mechanical Power Cords
Molded power cords are built using injection molding, a method that combines two or more materials with a plastic component molded over them to create a single part. This process consolidates the materials and parts to eliminate the need for additional assemblies. Also known as over-molded power cords for their forming technique, these cables are highly durable and secure.
For mechanical power cords, components such as the connector and plug must be manually hard-wired and joined to the cable. Also called “assembled” power cords for their labor-intensive assembly process, these cables can be manufactured with screw and clamp designs and often require tools to open the casing and other various electrical assemblies, including modification and wiring.
Benefits of Molded Power Cords & Assembled Power Cords
Molded Power Cord Advantages
The complete assembly of molded power cords provides enhanced reliability and flexibility. This durability makes over-molded cables excellent for a wide range of uses. Additional benefits of over-molded cord styles include:
- Flexible design options
- Less prone to damage
- Permanently sealed connections
- Protection from environmental impacts
- Reduced labor and manufacturing costs
- Strain relief for frequent usage
Assembled Power Cord Advantages
Manual assembly (as opposed to machine injection) increases customization options for mechanical power cables. Assembled power cords can be constructed by hand or with special equipment, with virtually endless configurations and compositions available. Additional benefits of assembled power cords include:
- Able to disconnect and reattach components
- High-quality components for longevity
- Option for post-installation assembly
Which Type of Power Cord is Right for You?
In most cases, molded power cords are the go-to option. Their durability and flexibility make them excellent for many applications, including medical equipment, industrial machinery, consumer electronics, automotive equipment, and portable devices.
However, assembled power cords are beneficial for various uses and may be the best option. These cables are ideal solutions for applications requiring ultra-specific cord lengths, routing cables through barriers, or constant changes in device placement. Mechanical power cords are found in the construction and manufacturing industries for applications including medical equipment, industrial machinery, data centers, and custom projects.
Find Your Best Power Cords at Quail Electronics, Inc.
At Quail Electronics, Inc., we stock an impressive selection of power cords and accessories in the styles you need. Our trained team members can answer any questions and help you choose the best types of power cords for your requirements. Contact us to learn more about molded and mechanical power cords. Request a quote to start an order today.