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.
Engineered from oxygen-free copper with silver-plated contact faces, these lugs maintain ≤0.5mV resistance even after 10,000 thermal cycles (-50°C to +120°C). The cross-grooved contact surface and lock-wire bolt system eliminate loosening in 10G vibration environments, proven in IEC 60068-2-6 testing.
Standard lugs struggle with current crowding above 3000A, but our cross-grooved contact design distributes load evenly across four pressure zones. Computational modeling shows 45% lower thermal rise at 5000A compared to conventional designs.
The silver-tin-nickel plating system creates triple corrosion protection which silver for conductivity, tin for moisture resistance, and nickel as a diffusion barrier. Partial discharge tests confirm 72kV performance with <5pC at 1.5Ur.
Need reliable Lugs for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Handles 72kV switching surges and 80kA fault currents in 500kV+ transmission systems, exceeding IEEE 386 Class II requirements.
CX-grade corrosion protection withstands salt spray for 2000+ hours, while the 12kg reinforced design survives hurricane-force vibrations.
5000A continuous rating with replaceable bi-metallic pads prevents galvanic corrosion at aluminum-copper interfaces.
Embedded RTD sensors monitor real-time temperature at valve halls, with 150°C emergency overload capacity.
Maintains bolt torque within 5% of spec after 1 million vibration cycles (EN 50155 certified).
Prevents arc faults in 480V busway connections, with silicone insulation guards for accidental contact protection.
Loose or failing connections in high-current systems cause dangerous arcing and costly downtime. Our Four-Bolt Transformer Lugs eliminate these risks with a quad-bolt design that distributes clamping force evenly across four pressure zones.
Independent testing confirms ≤0.5mV contact resistance even at 5000A loads and 10G vibration environments. We specialize in ultra-high-current solutions that outperform standard lugs by 60% in contact pressure and 45% in heat dissipation.
Check all our Frequently Asked Question
The symmetrical clamping force prevents uneven expansion that causes loose connections in single-bolt designs. Our testing shows the quad-bolt system maintains 95% of initial torque after 10,000 thermal cycles (-50°C to +120°C), far exceeding IEEE 386 requirements. This performance stems from the Belleville washers and cross-grooved contact surface working in tandem to compensate for material expansion.
While the upfront cost is higher, the total lifecycle savings are substantial – our field data shows 60% fewer maintenance interventions over 20 years compared to conventional lugs. We also offer scalable pricing models for large transmission projects that can reduce per-unit costs by up to 30% for bulk orders above 100 pieces.
Our rapid-response manufacturing cells can produce emergency replacements within 72 hours for critical failures. We maintain strategic copper stockpiles to ensure raw material availability, and all rush orders include expedited global shipping with real-time tracking.
The triple-layer plating creates a corrosion barrier that lasts 8x longer than standard tin plating in salt spray tests (2000+ hours per ISO 9227 CX). Our marine clients report zero degradation after 7 years in offshore wind farms, thanks to the nickel diffusion layer preventing subsurface corrosion.
The oxygen-free copper construction contains 92% recycled content without compromising conductivity, verified through SEM-EDS analysis. Our silver-tin-nickel plating process eliminates cyanide and other hazardous chemicals typically used in electroplating. These sustainable features qualify the lugs for LEED credits in green building projects, with full EPD declarations available upon request.
Submit the form below and our representative will be in touch shortly.
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!