Hot Glue Overmold for Anderson Powerpole

Two part mold to produce an overmold (more properly, an “insert mold”) around the incoming wires on the back of a pair of Anderson Powerpole connectors. Hot-melt glue from a hot glue gun is used in lieu of an actual injection-molding machine.

Especially when using smaller-gauge wire, the Powerpole connectors can create a tight bend radius and failure point at the back of the connector. This mold allows the space to be filled with thermoplastic, creating a strain relief.

Done well, it can also prevent moisture entry, but I haven't been able to get perfect results yet.

Printed from PLA+ (because the hot glue barely sticks to it) although other materials might work—you may need mold release agent if your material is particularly friendly with the glue you're using. Should probably also work with air-curing silicones and potting materials.

Uses 1/8" x 3/4" steel locating pins, available from Amazon or McMaster. They are meant to fit tightly into the bottom, and should be drifted in with a light hammer or mallet. On top they should be a tight running fit. Clamp the mold tightly closed before use with a C clamp or Vise-Grips.

Designs will be updated periodically if I refine them to work better.