Engine mounts, chassis parts, and machined components for assembly lines.
High-strength fasteners, landing gear parts, and structural assemblies.
Forged housings, armor brackets, and mission-critical structural parts.
Precision housings, actuator frames, and armature linkages for automation systems.
Metal frames, brackets, and assemblies for appliances and home equipment.
Busbar holders, battery pack parts, and lightweight structural enclosures.
Solar mounting parts, wind turbine brackets, and battery enclosures.
Valve bodies, flange blocks, and downhole drilling components.
Large welded frames, PEB structures, and assemblies for industrial equipment.
High-performance cables and wires engineered for durability and seamless connectivity across applications.
Custom-built wiring harnesses for secure connections and streamlined installations.
Precision-engineered busbars for efficient power distribution and minimal energy loss.
Robust connectors designed for secure locking, reliable conductivity, and long-term performance.
Durable transformers built for consistent performance, energy efficiency, and stable power regulation.
Frigate’s industrial-grade heat sinks provide efficient, customizable cooling for high-performance thermal management.
Diverse solutions covering automotive, electrical, mechanical, and industrial needs with precision-built components.
CNC machining delivers micron precision and tight tolerances for complex geometry.
Frigate CNC Machining offers high-precision, custom solutions for complex casting geometries. Multi-axis capabilities ensure tight tolerances and optimal surface finishes.
Sheet metal fabrication uses laser cutting, punching, and bending for precision.
Frigate Sheet Metal Fabrication utilizes advanced laser cutting and press brake technology for custom casting applications. Tight tolerances, superior welds, and high-strength materials ensure structural integrity.
Injection molding produces high-precision parts with consistent quality.
Frigate Injection Molding delivers custom-engineered parts with micron-level precision and structural integrity. Specialized molds maintain tight tolerances for complex geometries and high-stress applications.
Precision casting ensures accurate, high-quality parts.
Forging services improve material strength with precise tolerances.
Frigate Casting Services provides custom casting with tight tolerances and complex geometries. We enhance material properties using advanced metallurgy, ensuring strength and wear resistance. Our precision methods support high-performance aerospace, automotive, and industrial applications.
End-to-end part production from samples to bulk supply.
Ready-to-use assemblies built to exact fit and function.
Heavy-duty fabrication with high-strength materials for demanding applications. Robust welding for maximum structural durability.
Unlike makeshift solutions, these lugs feature a 15° transition zone that reduces current crowding by 40%, verified by thermal imaging at 1200A loads. The dual-compression design ensures UL 486B and IEC 61238-1 compliance, eliminating the safety risks of improvised connections.
Reducer lugs often fail at the taper point, but our 6063-T6 alloy maintains 200MPa tensile strength across the transition zone. The progressive crimping system applies 40-100kN force in sequence, ensuring equal compression on both conductor sizes.
Third-party testing confirms 750-hour salt spray resistance (C4 rating) and 35kV partial discharge performance. Laser-etched size markings on both ends prevent installation errors during maintenance or upgrades.
Need reliable Lugs for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Transition between main collector cables (400mm²) and inverter inputs (240mm²) while withstanding 35kV surges in solar/wind installations.
Adapt older 300mm² busbars to modern 150mm² equipment feeds without costly panel modifications in factory retrofits.
Manage precise ampacity transitions between PDUs and server racks, maintaining <1% voltage drop across size changes.
Salt-resistant tinned lugs connect generator outputs (350mm²) to distribution panels (185mm²) in confined engine rooms.
Vibration-proof design handles 3:1 reductions in overhead catenary systems, compliant with EN 50152-1.
Withstand 10G vibration while transitioning 240mm² power feeds to 95mm² drill motor connections.
Contractors save 60% labor time compared to splicing kits, with no special tools required beyond standard crimpers. Each lug ships with a matched die chart for both barrel sizes, eliminating guesswork in the field.
Procurement teams benefit from stocked size pairs (50-400mm² → 16-240mm²) with full traceability documentation. Custom-marked versions include project IDs and installation dates for asset management compliance.
Check all our Frequently Asked Question
The gradual taper reduces current density spikes by 40% at transition points, verified by infrared thermography at 1200A loads. Unlike abrupt step-down designs, this maintains uniform heat distribution across both conductor sizes. Our testing shows ≤5°C temperature differential even at maximum rated current.
No, each lug is precision-engineered for a single ratio to ensure proper compression depth on both conductors. We stock 18 standard ratios (1.5:1 to 3:1) and offer custom dies for unique requirements. Mismatched ratios risk under-compression and hot spots.
Every shipment includes IEC 61238-1 Class A test reports with dual-conductor crimp samples, LME aluminum traceability certs, and 35kV partial discharge test data. For North America, we provide UL 486B files with NEMA-approved crimp die charts.
Laser-etched arrows indicate the proper crimping sequence (large→small conductor), while color-coded die charts match our tooling partners (Greenlee, Klauke). Training videos showing the 2-step crimp process are available via QR code on each lug.
Standard configurations ship in 7 days, while custom Cu-Al transitions require 14 days for plating validation. Rush service (72 hours) is available for emergency, with prototype test reports provided before full production.
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818, Preakness lane, Coppell, Texas, USA – 75019
23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ
FRIGATE is a B2B manufacturing company that facilitates New Product Development, contract manufacturing, parallel manufacturing, and more, leveraging its extensive partner networks.
Need reliable wires and cables for your next project? Get in touch with us today, and we’ll help you find exactly what you need!