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.
Copper, aluminum, or alloys for optimal electrical performance.
3-8 microns for enhanced conductivity and corrosion resistance.
1-6 mm for efficient power distribution and thermal management.
10-150 mm to fit various system designs and space requirements.
>98% IACS for minimal power loss and optimal energy transfer.
Overmolded busbars are a highly effective solution for addressing common challenges in electrical connectivity. With their compact design, superior durability, efficient heat dissipation, fast assembly, and precise electrical performance, they provide a reliable and cost-effective way to enhance the efficiency and longevity of electrical systems. Their versatility and customization options make them ideal for various industries, ensuring that systems are optimized for performance and functionality.
Copper: 398 W/m·K; Aluminum: 205 W/m·K for effective heat dissipation.
Up to 1000 V DC/AC for reliable power distribution in systems.
100-1000 A based on size and system current handling needs.
-40°C to +125°C for reliable operation in extreme temperatures.
Highly resistant to environmental factors like moisture and chemicals.
Copper: 210 MPa; Aluminum: 130 MPa for strong, durable connections.
Excellent adhesion for long-lasting performance under mechanical stress.
Smooth, high-quality finish to reduce electrical resistance.
Custom shapes, sizes, and configurations tailored to system needs.
Complies with RoHS, UL, ISO 9001, IEC 60269, MIL-STD-202 standards.
The overmolding process encapsulates electrical conductors within a protective layer, making overmolded busbars highly resistant to external factors like moisture, chemicals, and vibration. This enhanced durability ensures that the busbars perform reliably in demanding environments, extending the system’s lifespan and reducing the risk of failures due to environmental damage.
Managing heat in electrical systems is crucial for preventing damage and maintaining long-term performance. Overmolded busbars excel in heat dissipation, ensuring electrical components remain at safe operating temperatures even under high-current conditions. The materials used in overmolding facilitate efficient thermal management, preventing overheating and enhancing the system’s overall reliability.
Need reliable Bus Bars for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Overmolded busbars efficiently distribute high currents from battery packs to powertrain components, ensuring stable and low-resistance connections in confined spaces.
In aerospace, overmolded busbars integrate power distribution for avionics and control systems, minimizing weight while maintaining high electrical conductivity and thermal stability under fluctuating operational conditions.
Overmolded busbars are employed in high-power DC-DC converters to efficiently transfer power between photovoltaic modules and inverters, reducing power losses and ensuring reliable connections in harsh environmental conditions.
Overmolded busbars are utilized in uninterruptible power supplies (UPS) to handle high-current flow between rectifiers and inverters, with optimal heat dissipation and minimal voltage drop during power transition events.
These busbars facilitate the distribution of high currents from locomotive traction batteries to the electric traction motors, ensuring thermal stability and resistance to vibrations and shocks during operation.
In large-scale data centers, overmolded busbars provide low-resistance power connections for server racks and cooling systems, ensuring thermal management and preventing signal interference in high-density layouts.
Overmolded busbars are designed for quick and easy integration, minimizing assembly complexity and time required. The pre-molded design reduces the need for additional connectors, cables, or manual wiring, resulting in faster installation and lower labor costs. This contributes to more streamlined manufacturing processes, improving overall production efficiency.
These busbars are engineered to provide precise electrical performance, handling high-current applications without signal degradation or power loss. The materials and design of overmolded busbars ensure optimal conductivity, minimizing electrical resistance and ensuring stable power delivery, which is essential for high-performance systems.
Check all our Frequently Asked Question
Overmolded busbars are designed with materials that facilitate superior heat transfer. The overmolding encapsulates the conductors to maximize surface area, allowing heat to dissipate more efficiently. This design minimizes the risk of overheating by spreading the heat across the surface, ensuring that the system operates at safe temperatures even in high-current environments.
The materials used in overmolded busbars, such as copper or aluminum alloys, are chosen for their high conductivity. The overmolding process ensures the electrical pathways remain uninterrupted and smooth, reducing electrical resistance. This results in more efficient power delivery with minimal energy loss, crucial for maintaining stable operation in high-power applications.
Overmolding materials like thermoplastics protect against environmental factors like moisture, dust, and chemicals. This ensures the electrical conductors remain insulated and safe from corrosion, oxidation, or physical damage. The overmolded layer also reduces the effects of vibration, which can degrade the performance of traditional, unprotected connectors.
Overmolded busbars can be designed with shielding materials or specific geometries that help reduce electromagnetic interference (EMI). The molded layer can act as a barrier that absorbs or deflects EMI, ensuring that electrical signals remain stable and interference from external sources is minimized. This is especially important in sensitive electronic equipment or communication systems where noise can disrupt performance.
Yes, overmolded busbars are highly customizable to meet unique electrical requirements. They can be tailored in shape, size, and configuration to fit complex layouts or limited spaces. Custom overmolding ensures that the busbars integrate seamlessly with other components, providing optimal conductivity and performance while saving space and reducing the need for additional wiring or connectors.
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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!