Custom Molded DC Power Cords

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. 

Conductor Material

High-purity annealed copper 

Insulation Material

PVC, XLPE, or rubber insulation 

Voltage Rating

Suitable for up to 600/1000V applications

Temperature Range

Operates efficiently between -40°C to +90°C 

Fire Resistance

Operates efficiently between -40°C to +90°C 

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. 

Water Resistance

IP68 rated, providing complete protection against continuous immersion in water. 

UV Resistance

UV stabilized sheath material to prevent degradation from prolonged exposure to sunlight. 

Cross-sectional Area

Available from 1.5mm² to 400mm² 

Sheath Material

PVC, LSZH. and Rubber Sheath 

Armoring

Steel Wire Armour (SWA), Aluminum Wire Armour (AWA) 

Armoring

Steel Wire Armour (SWA), Aluminum Wire Armour (AWA) 

Armoring

Steel Wire Armour (SWA), Aluminum Wire Armour (AWA) 

Armoring

Steel Wire Armour (SWA), Aluminum Wire Armour (AWA) 

Armoring

Steel Wire Armour (SWA), Aluminum Wire Armour (AWA) 

Armoring

Steel Wire Armour (SWA), Aluminum Wire Armour (AWA) 

Product Description

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Need reliable Heat Sinks for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Wiring Harness

Photovoltaic Systems

Connect Photovoltaic Systems solar panels to inverters, ensuring efficient energy transfer in grid-tied and off-grid installations. 

Solar Farms

Interconnect Solar Farms with multiple solar arrays, enabling large-scale energy production while maintaining low resistance and minimizing voltage drop. 

Rooftop Solar Panels

Facilitate the connection between Rooftop Solar Panels and electrical systems, providing optimal energy management in urban settings. 

Battery Storage Systems

Link solar panels to Battery Storage Systems, allowing for energy retention and stable power supply during low sunlight. 

EV Charging Infrastructure

Integrate solar energy into EV Charging Infrastructure, optimizing renewable energy use for vehicle charging.

Irrigation Systems

Support solar-powered Irrigation Systems, enabling sustainable farming practices by powering pumps and equipment. 

Wiring Harness

“Solar BOS” stands for “Balance of System” in the context of solar energy systems. It refers to all the components and equipment, aside from the solar panels themselves, that are necessary for the operation and functionality of a solar power system. It refers to all the components and equipment, aside from the solar panels themselves, that are necessary for the operation and functionality of a solar power system.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

What is your maximum CNC machining part size?

For milling Frigate supports parts up to 80” x 48” x 24” (2,032 x 1,219 x 610 mm) & for Lathe machining, we support parts up to 62” (1,575 mm) length and 32” (813 mm) diameter. 

In VMC, we have 600mm*600mm*600mm table capacity when it comes to 5 axis and up to 3 meters when it comes to 3 axis machining & up to 1 meter when it comes to 4 axis.

What are your General Tolerances?

Tolerances as per ISO 2768 unless otherwise specified. Maximum tolerance for plastics and composites will be +/- 0.010”. 

Can we get separate surface finishes?

The standard finish is as-machined: 125 Ra or better. However, Frigate would be happy to support requests of any specific surface finish. Please let us know what type of surface finish would meet your requirements when asking for our quote. 

Does Frigate offer CNC machining for Thread and Tapped holes?

Frigate can accommodate any standard thread size. We can also machine custom threads; these will require a manual quote review. 

What are the materials we handle for CNC machining?

All kinds of metals & non-metals, woods, acrylics, foams, Delrin, nylon, PTFE(Teflon) and other thermoplastic materials. 

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

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

Other Locations

GENERAL ENQUIRIES

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Custom Molded DC Power Cords

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!

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Custom Molded DC Power Cords

Need reliable Machining for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Get Latest Price

Get Price Form