Custom Molded DC Power Cords

Name: EMI Shielding Custom Molded DC Power Cords | UL & FCC Approved - Frigate
Price: 249.00 USD
Availability: InStock

Custom Molded DC Power Cords assemblies utilize precision-molded thermoplastics to encapsulate connectors and eliminate mechanical loosening under axial pull, torsion, and vibrational loads. Retention forces exceed 75 N axial and 25 N lateral based on ASTM D4565 and IEC 61076. The molded interface is shaped to match exact connector geometries, maintaining contact stability in mobile and industrial equipment.

Connector Barrel Diameter

Customizable: 1.3 mm to 5.5 mm ±0.05 mm

Center Pin Tolerance

±0.03 mm concentricity with respect to barrel axis

Overmold Material Options

PVC, TPU, TPE, Polyurethane (UL 94 V-0 rated)

Flex Cycle Durability

>1 million cycles at ±90° bend radius per UL 758

Voltage Rating

Up to 60 VDC continuous operation

Product Description

Custom Molded DC Power Cord constructions employ high-strand-count conductors and overmolded strain reliefs with controlled durometer profiles. Finite Element Analysis (FEA) guides tooling to reduce stress concentration near connector terminations. Assemblies are rated to exceed 1 million flex cycles at ±90° bend radius in accordance with UL 758 and ISO 14572 dynamic testing protocols.

Current Carrying Capacity

Up to 10 A at 12 VDC with <30°C rise

Ingress Protection Rating

Up to IP68 sealed (based on overmold geometry and compound selection)

Conductor Size Range

12 AWG to 24 AWG stranded copper

Contact Resistance

<10 milliohms measured end-to-end after assembly

Hi-Pot Withstand Voltage

1500 VDC for 60 seconds with no breakdown (per UL 2238)

Insulation Resistance

>100 MΩ @ 500 VDC under 95% RH, 96 hrs (per IEC 60245)

Shielding Options

100% foil with drain wire or 85% tinned copper braid, grounded at overmold

Operating Temperature Range

−40°C to +125°C depending on compound used

Barrel Contact Plating

Nickel, Tin, or Gold flash over nickel; 1–5 µm thickness

>150 N axial pull force on molded strain relief per ASTM D4565

Technical Advantages

Sealed molding compounds such as TPV, TPU, and halogen-free TPE provide ingress protection up to IP68 for Custom Molded DC Power Cord assemblies. Material interfaces are fused through precision injection tooling that eliminates air voids and capillary ingress points. Sealing integrity is validated by pressure decay and immersion testing per IEC 60529 and MIL-STD-810G standards.

Custom Molded DC Power Cord geometry can be configured to accommodate proprietary device housings, PCB recesses, or enclosure cutouts. Barrel diameters, shell length, and center-pin depth can be specified within ±0.1 mm tolerances. Custom keying, locking grooves, and non-symmetrical molds allow mis-mating prevention for sensitive power applications.

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Industry Applications

Industrial Automation Equipment

Provides secure low-voltage power delivery in servo drives, PLC modules, and actuators exposed to vibration, bending, and thermal cycling.

Medical Diagnostic Devices

Ensures stable power to imaging systems, analyzers, and pumps requiring sealed connectors and high EMI/RFI immunity in patient environments.

Telecommunications Infrastructure

Delivers regulated DC power to base stations, routers, and edge devices with custom mating interfaces and minimal voltage drop across distances.

Electric Mobility Systems

Powers battery management modules, motor controllers, and DC-DC converters in e-bikes, scooters, and light EVs with flexible overmolded strain relief.

Embedded Computing and IoT Devices

Supports custom connector footprints in compact enclosures for SBCs, gateways, and sensors requiring tight tolerance and thermally stable interconnects.

Defense and Aerospace Electronics

Operates in ruggedized systems like UAVs, radios, and field equipment with MIL-grade materials rated for shock, altitude, and moisture ingress protection.

Voltage Drop Minimization Across Extended Lengths

Custom Molded DC Power Cord assemblies are engineered with conductor gauges up to 12 AWG and terminal crimp resistance <1 mΩ. Full-length voltage drop is maintained below 2% under continuous DC load, verified by load bank simulation. Cords support up to 10 A at 12 VDC or 5 A at 24 VDC without exceeding 30°C temperature rise at maximum load.

Custom Molded DC Power Cord shielding options include 100% aluminum-mylar wrap and 85% coverage tinned copper braid, terminated directly to the overmold with conductive adhesive interfaces. Shielded cords are impedance-matched and include optional integrated ferrite cores. Assemblies comply with Class B radiated emission limits per CISPR 22 and EN 55032.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure dimensional accuracy in custom molded DC connectors?

Frigate uses CNC-machined mold inserts with dimensional tolerances of ±25 microns. Pin and shell alignment is controlled with precision core pins and steel inserts during molding. Each connector is verified using digital profile projectors and pin gauge testing. This ensures perfect fit into mating jacks and eliminates mechanical misalignment.

What testing does Frigate perform on molded DC cords for high-current applications?

Fregatte conducts high-current load testing using programmable DC loads to simulate 100% duty cycle. Voltage drop and thermal rise are monitored over continuous operation at specified current levels. All cords are tested to ensure conductor resistance stays below 10 mΩ and temperature rise below 30°C. These tests follow UL 2238 and IEC 60245 performance criteria.

Can Frigate design custom molded DC cords for low-temperature or outdoor deployment?

Yes, Frigate selects TPE or TPU compounds rated for −40°C and UV/weather resistance. Material properties are verified per ASTM D746 for brittleness and ASTM G154 for UV exposure. Molds are designed to minimize moisture ingress by integrating seal lips and compression geometry. Finished Power cords undergo cold impact and freeze-thaw testing to ensure reliability in outdoor environments.

How does Frigate handle polarity-specific or keyed DC barrel designs?

Frigate supports custom inner pin sizes, offset tips, and keyed barrel configurations to prevent reverse polarity connections. Mold tooling is designed to accommodate custom shell profiles with asymmetrical locking notches. Polarity is verified electrically and visually during final QC. All designs are documented and serialized for repeatable production.

What quality controls does Frigate apply during overmolding of DC power cords?

Frigate uses automated pressure and temperature monitoring during the molding cycle to control resin flow and prevent voids or overflash. Each batch undergoes visual inspection, pull-force testing, and continuity checks. Statistical process control (SPC) is maintained on cavity fill, pin placement, and jacket bonding. This ensures consistent quality across high-volume runs.

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LOCATIONS

Sitz

10-A, First Floor, V. V Komplex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, Indien.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti Coimbatore-641035, Tamil Nadu, Indien. ㅤ

Custom Molded DC Power Cords

Connector Barrel Diameter

Center Pin Tolerance

Overmold Material Options

Flex Cycle Durability

Voltage Rating

Product Description

Current Carrying Capacity

Ingress Protection Rating

Conductor Size Range

Contact Resistance

Hi-Pot Withstand Voltage

Insulation Resistance

Shielding Options

Operating Temperature Range

Barrel Contact Plating

>150 N axial pull force on molded strain relief per ASTM D4565

Technical Advantages

Let's Get Started

Industry Applications

Voltage Drop Minimization Across Extended Lengths

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Custom Molded DC Power Cords

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Custom Molded DC Power Cords

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