One of our customers needed a military grade communication assembly that could withstand water immersion. One of the design elements gave them trouble: a molded splice junction. The original design required multiple injection molding steps but still did not create a reliable seal against water. As a result, the assembly repeatedly failed leak testing and required additional sealant applications.
To solve the leaky seal, we designed and incorporated an ultrasonically welded shell to enclose the junction. The manufacturing process was reduced to a one-step molding operation that created a secure water seal. The new welded shell passed 99% of leak tests and eliminated the need for multiple sealant applications. The design enhancements also reduced process time by 10%.