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.
Precision-machined from high-conductivity copper (C11000) with tin-plated contact surfaces, these lugs maintain ≤1mV contact resistance at 2000A loads. The serrated contact face and Belleville washer system prevent loosening, validated by 1000-hour vibration testing per IEC 60068-2-6.
The dual-bolt system distributes clamping force evenly across the conductor, reducing contact resistance by 30% compared to single-bolt designs. Finite element analysis confirms uniform pressure distribution even after 5000 thermal cycles (-40°C to +105°C).
Our proprietary tin plating process (8-12μm) combines with optional silver contact faces to create a dual-barrier against oxidation. Testing shows 0.02% annual resistance change in damp heat conditions (85°C/85% RH), outperforming standard lugs by 5x.
Need reliable Lugs for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Withstands 35kV switching surges and 50kA fault currents, complying with IEEE 386 for pad-mounted transformers.
UV-resistant design endures 3000+ sun hours in solar farms while preventing galvanic corrosion at aluminum-copper interfaces in wind turbine step-up transformers.
Dual-bolt redundancy ensures stable connections for critical loads in steel mills and data centers, with 105°C continuous temperature rating.
Vibration-proof construction meets EN 50155 shock requirements for locomotive transformers and catenary connections.
CX-grade salt spray resistance (1000+ hours) prevents degradation in harsh coastal environments.
Reinforced 25mm thickness handles 10G vibrations in mobile substations and shovel power systems.
Engineers can specify with confidence knowing these lugs are pre-validated for the most demanding transformer applications, with 35kV and 50kA ratings that exceed typical grid requirements. The combination of dual-bolt security and optimized plating ensures consistent performance across decades of service, reducing lifecycle costs through minimized maintenance.
For seamless integration, we provide complete technical packages including CAD models, torque specifications, and regional compliance documentation. Our global manufacturing footprint supports rapid delivery, while material traceability guarantees quality from raw copper to finished product.
Check all our Frequently Asked Question
The balanced clamping force from two bolts distributes contact pressure evenly, reducing hot spots by 40% at 2000A loads. Our testing confirms ≤1mV contact resistance even after 5000 thermal cycles (-40°C to +105°C), outperforming single-bolt designs. The serrated contact surface and Belleville washers further maintain stable conductivity under vibration, as verified by IEC 60068-2-6 testing.
The balanced clamping force prevents uneven thermal expansion that leads to loose connections, a common failure point in single-bolt designs. Field data from utility substations shows zero reported incidents of hot spots or arcing after 10+ years of service. This reliability translates to fewer unplanned outages and lower maintenance costs over the 30-year design life.
Independent testing confirms compliance with UL 486A-B for 2000A continuous current and IEC 61439 for 35kV dielectric strength. The lugs also meet IEEE 386 requirements for transformer connections, including 50kA short-circuit withstand capability. Full test reports are included with every shipment for immediate compliance verification.
The 8-12μm tin base layer provides cathodic protection, while the optional 15μm silver plating resists sulfur and salt corrosion. Our coastal clients report zero degradation after 5 years in C5 environments, backed by 1000-hour salt spray testing per ISO 9227. This dual-layer approach outperforms standard tin plating by 8x in marine acceleration tests.
The Belleville washer system maintains 90% of initial clamping force even after 10,000+ vibration cycles at 10G acceleration (IEC 60068-2-6 tested). Our dual-bolt design incorporates serrated contact faces that “bite” into conductors, preventing slippage under dynamic loads. Field installations in wind turbine step-up transformers show zero torque loss after 5 years of continuous operation.
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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!