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.
Durable transformers built for consistent performance, energy efficiency, and stable power regulation.
Frigate’s industrial-grade enclosures provide durable, customizable protection with efficient thermal management for high-performance applications.
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.
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.
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.
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.
Need reliable Heat Sinks for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Provides secure low-voltage power delivery in servo drives, PLC modules, and actuators exposed to vibration, bending, and thermal cycling.
Ensures stable power to imaging systems, analyzers, and pumps requiring sealed connectors and high EMI/RFI immunity in patient environments.
Delivers regulated DC power to base stations, routers, and edge devices with custom mating interfaces and minimal voltage drop across distances.
Powers battery management modules, motor controllers, and DC-DC converters in e-bikes, scooters, and light EVs with flexible overmolded strain relief.
Supports custom connector footprints in compact enclosures for SBCs, gateways, and sensors requiring tight tolerance and thermally stable interconnects.
Operates in ruggedized systems like UAVs, radios, and field equipment with MIL-grade materials rated for shock, altitude, and moisture ingress protection.
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.
Check all our Frequently Asked Question
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.
Frigate 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.
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.
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.
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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10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, 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!
Need reliable Machining for your next project? Get in touch with us today, and we’ll help you find exactly what you need!