Cable assembly having thermoplastic overmold

An optical fiber cable assembly, comprising:

• a distribution cable containing a plurality of optical elements and having an opening formed in the distribution cable;
• a branch cable having a bore extending along a length thereof, the branch cable comprising at least one tether;
• and
• a thermoplastic overmold;
• wherein at least one optical element of the plurality of optical elements extends from the distribution cable through the opening and into the bore of the branch cable;
• wherein the thermoplastic overmold is formed around the opening of the distribution cable, an end of the branch cable, and at least a portion of the at least one optical element;
• and
• wherein a bonding force between the thermoplastic overmold, an outer surface of the distribution cable, and an outer surface of the branch cable is greater than 100 lbf.

A method of forming an overmold around a distribution cable and a branch cable in which a first optical element extends from the distribution cable into the branch cable, comprising:

• positioning a distribution cable within a mold such that the distribution cable is supported by a structure within the mold, the distribution cable containing a plurality of optical elements, including the first optical element, and the distribution cable having an opening formed therein through which the first optical element extends, the opening being within the mold;
• positioning a branch cable within the mold;
• and
• injecting a thermoplastic material into the mold to form the overmold around the opening of the distribution cable, an end of the branch cable, and at least a portion of the first optical element.