[aprssig] Making molded connectors and potting

Keith Kotch kkotch at earthlink.net
Mon May 23 14:48:25 EDT 2005

In my line of work, one of our customers is a major avionics manufacturer
for whom I do some environmental monitoring in their production facilities.
One of the rooms that I check is where they pot electronics and crt
displays.  I always like to see these processes and it spurs me to think how
nice I could make projects look and last if I adopted such concepts as
potting and creating molded connectors.


In asking around it was suggested that I look in Arts and Crafts stores for
molding supplies.  I did run across this company at a local store:


Looking at some disc samples of the different molding compounds makes this
stuff look promising.  I don't know about dielectric properties of the
material but since it's rubber-like or plastic-like in some forms I don't
think that would be a problem.


Keith, KF4BXT



From: scott at opentrac.org
Subject: RE: [aprssig] FW: D-sub connector components


Digi-Key and Mouser should both have all of those parts.  I can suggest some
part numbers for the 9-pin connectors and backshells.  I carry those on my
own site as well:  http://n1vg.net/opentracker/purchase.php


The backshells come with all the hardware.  For the side connecting to the
GPS cable, you might want connectors with integrated clinch nuts.  Digi-Key
carries a couple thousand d-sub connectors and they've got the best
parametric search around.


Let me know if you find any good homebrew techniques for overmolding.  I've
done some stuff with hot melt glue when necessary, but that's about it.  I
need some custom molding myself - I've got to make cables for Motorola
handhelds, and the spacing between the 2.5 and 3.5 mm plugs is too small for
separate connectors.  Mouser sells plugs designed for overmolding, but aside
from investing some serious money in tooling and injection molding, I don't
know how you'd use them.




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