Abstract: A connector For wires to be connected in harsh environment applications. This approach uses low pressure casting techniques. An alternative embodiment uses a thin, rigid stabilizer to position one or more contacts inside of the connector shell. Foamed polyurethane is injected inside the connector shell in liquid form. This encapsulates the stabilizer (when used) and forms an insulator around the contacts and wires. The polyurethane is bonded to the inside of the connector shell. The bonding strength of the polyurethane will form an environmental seal suitable for harsh environmental applications. In some cases a primer may be pre-applied to the inside of the connector shell the contacts, the wires, or the stabilizer to enhance the bonding of the polyurethane.