Plastic Molding
Plastic molding plays a critical role in high-voltage insulation, enabling safe, compact, and reliable designs for EV and energy systems. Compared to sleeving or tape, molded insulation offers superior dielectric strength,
touch-safe protection, and dimensional precision—while reducing manual labor and assembly steps. Connor supports insert molding, overmolding, and hybrid construction using UL-rated, flame-retardant resins. Our Mold Flow Analysis helps optimize designs early in DFM, predicting shrinkage, warpage, and fiber orientation before tooling cut. By integrating molding with busbar forming and welding, we deliver fully encapsulated or selectively insulated components—engineered for thermal, electrical, and vibration performance in PDUs, BMS, battery junctions, and structural interconnects.
- Mold Flow Analysis during early-stage DFM for shrinkage, warpage, and fiber prediction
- Insert molding for high-precision copper and aluminum terminals
- Overmolding for metal encapsulation using UL-rated engineering resins
- Enhances insulation, vibration resistance, and thermal protection in HV assemblies
- Supports flame-retardant and dielectric barrier requirements for touch-safe designs
- Consistent wall thickness, seal integrity, and part repeatability
- Integration with stamping and assembly for fully molded electrical interconnects
- Hybrid assemblies combining metal, plastic, and welded joints in one process
- Designed for PDU, BMS, and junction module applications in EV and energy systems