Electronics > Projects, Designs, and Technical Stuff

How to imitate molded power cord strain relief?

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rcbuck:
Is there a way to somewhat imitate the flexible strain relief that is used on the connector end of a walwart? Pix1 is typical walwart. Pix2 and pix3 are the DC connectors that are available from DK and Mouser (CUI PP3-050A ).

The best I have been able to do is squeeze silicone glue into the end of the plug. It works but looks kind of cheesy. Maybe there is a way to eliminate the plastic cap and mold some type of rubber around the metal part after attaching the wires?

james_s:
I typically use a piece of heatshrink tubing over the wire. If I want to get fancy I'll sometimes use multiple layers with each being a little shorter than the one under it. Shrink it over the metal structure that clamps the wire and it will normally be fairly secure.

rcbuck:
I guess that would work but heat shrink tends to be fairly stiff after it shrinks.

Silicone rubber would be better but I don't think you can get it in small quantities. For a few uses per year the large quantity kits are expensive and I sure it has limited shelf life.

tooki:

--- Quote from: james_s on October 15, 2021, 12:43:20 am ---I typically use a piece of heatshrink tubing over the wire. If I want to get fancy I'll sometimes use multiple layers with each being a little shorter than the one under it. Shrink it over the metal structure that clamps the wire and it will normally be fairly secure.

--- End quote ---
I do it exactly the same way! :)


--- Quote from: rcbuck on October 15, 2021, 06:08:34 am ---I guess that would work but heat shrink tends to be fairly stiff after it shrinks.

--- End quote ---
Heatshrink tubing varies wildly in flexibility. You can get heatshrink that remains highly flexible.

TERRA Operative:
I also do the heatshrink thing.

I wonder if you could 3D print a mould to surround the end of the plug and wire and inject black silicone caulking inside?
I've had good success with 3D printing moulds to make silicone sleeves for the 3D printer hot end using high-temp automotive silicone gasket caulking.

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