DC Power Cords Assemblies

Our DC power cords assemblies incorporate high-conductivity materials, such as oxygen-free copper (OFC) or silver-plated conductors, optimized for low resistance and minimal voltage drop. The connector interfaces are precision-engineered with gold or nickel plating to reduce contact degradation and maintain consistent electrical performance over extended use.  

Conductor Material

High-purity copper (OFC), tinned copper, or aluminum for low resistance and high conductivity

Conductor Stranding

Finely stranded (Class 5/6 per IEC 60228) for flexibility or solid core for rigidity

Voltage Rating

Up to 600V DC (customizable based on application requirements)

Current Rating

5A to 300A depending on conductor size and application

Insulation Material

PVC, XLPE, silicone, or PTFE for high thermal stability and dielectric strength

Product Description

The conductors in our power cords are sized and rated according to the American Wire Gauge (AWG) standard, ensuring optimal current-carrying capacity for specific load requirements. Thermal derating factors are applied to account for environmental and operational temperature variations, ensuring safety and compliance with standards like IEC 60228. 

Insulation Resistance

PVC, XLPE, silicone, or PTFE for high thermal stability and dielectric strength

Jacket Material

PVC, TPE, PUR, or fluoropolymers for chemical, abrasion, and UV resistance

Jacket Thickness

0.8 mm to 2.5 mm depending on cable size and environmental requirements

Temperature Range

-55°C to +200°C depending on material selection

Flame Retardancy

UL94 V-0 or equivalent compliance for fire safety

Shielding

Braided copper, aluminum foil, or composite shielding with ≥85% coverage

Connector Type

Barrel, Anderson Powerpole, Molex, or custom connectors based on client specifications

Power Rating

50W to 10kW depending on load and system requirements

Environmental Rating

IP65 to IP68 for protection against dust and water ingress

Certification

UL, CSA, RoHS, REACH, CE, and ISO 9001 compliant

Technical Advantages

Improper current handling can lead to overheating, voltage irregularities, or cable failure. Our DC power cords assemblies are designed to match specific load requirements, with conductors sized according to the American Wire Gauge (AWG) standard for optimal current-carrying capacity. Thermal derating factors are applied to account for ambient temperature variations, ensuring safety and operational efficiency. Connector designs undergo thermal rise testing and contact resistance evaluation to validate their performance under maximum load conditions. Overmolding techniques are incorporated to enhance thermal dissipation and provide additional mechanical stability at connection points. 

Off-the-shelf solutions often fail to meet unique system requirements. Our DC power cords assemblies are custom-engineered to address such limitations. Connector options range from standard barrel types to proprietary designs, ensuring compatibility with specialized equipment. Cables can be tailored in length, flexibility, and voltage ratings to suit constrained spaces or repetitive motion applications. Hybrid configurations combining power and signal lines are also available for applications requiring multi-functional interfaces. Each assembly is precision-manufactured to tight tolerances, ensuring seamless integration with client systems. 

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Industry Applications

Military and Defense Systems

Powering radar systems, tactical communication equipment, and mobile command centers with ruggedized DC power connections. 

Energy Storage Solutions

Supporting battery management systems (BMS) and DC-based energy storage units in grid and off-grid setups. 

Semiconductor Manufacturing

Supplying ultra-stable DC power to lithography tools, etching machines, and wafer inspection systems in cleanroom environments. 

Railway and Transportation

Powering signaling systems, onboard electronic equipment, and auxiliary systems in locomotives and railcars. 

Test and Measurement Equipment

Delivering precise DC power to oscilloscopes, signal analyzers, and calibration instruments for laboratory-grade accuracy. 

Satellite Systems

Providing reliable DC power for communication payloads, navigation modules, and telemetry systems in space-grade environments. 

Compliance with Industry Standards

Failure to meet regulatory standards can result in operational risks or market non-compliance. Our DC power cords assemblies adhere to rigorous industry standards, including UL, CSA, RoHS, REACH, and CE certifications. These standards guarantee electrical safety, environmental responsibility, and product reliability. Additionally, cables are subjected to advanced reliability tests, such as high-current endurance, flex testing, and cyclic bending simulations, ensuring compliance with global benchmarks. This attention to detail ensures that our assemblies are ready for deployment in regulated markets without additional modifications. 

Mechanical wear, operational stress, and vibration are common causes of cable failure. Our DC power cords assemblies incorporate dual-layer insulation to enhance durability for superior dielectric strength and mechanical resilience. Strain reliefs are molded or clamped at terminations to distribute mechanical stress evenly, preventing wire fatigue and breakage. Locking mechanisms on connectors ensure secure connections in high-vibration environments, such as automotive or aerospace systems. Our cables are validated against MIL-STD-202 standards for vibration and shock resistance, making them suitable for extreme operating conditions. 

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure precise current distribution in custom DC power cords?

Frigate designs DC power cords with carefully calculated conductor sizes, ensuring minimal resistance and optimal current distribution. Advanced simulation tools verify uniform current flow under varying load conditions, reducing hotspots and ensuring cable longevity. 

What testing protocols does Frigate use to validate the durability of DC power cord assemblies?

Frigate subjects DC power cords to rigorous tests, including thermal cycling, flexural fatigue, and vibration testing, in compliance with MIL-STD-202 and IEC 60502 standards. This ensures the assemblies perform reliably under mechanical and environmental stress. 

How does Frigate address high-frequency noise in DC applications?

Frigate employs multi-layered shielding and ferrite bead integration in its DC power cord designs to suppress high-frequency electromagnetic interference (EMI). These measures ensure signal integrity in sensitive applications like aerospace or medical devices. 

Can Frigate manufacture DC power cords for extreme temperature environments?

Yes, Frigate specializes in cables ranging from -55°C to +200°C. Frigate uses materials like silicone, PTFE, and high-performance thermoplastics to ensure stable performance in both cryogenic and high-temperature conditions. 

How does Frigate design DC power cords for high-flex applications?

Frigate uses finely stranded conductors and high-flex insulation materials like TPE or PUR for repetitive motion environments. These designs undergo dynamic flex testing to meet the demands of automation, robotics, and other high-movement systems. 

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur,  Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

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

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DC Power Cords Assemblies

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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