Current Sensing & Shunt Solutions
Overmolded Shunt Assemblies
Compact, high-performance solutions for power monitoring and distribution in electric and hybrid vehicles.
Overmolded Shunt Assemblies for High-Current EV Systems
Engineered for precision and durability, these assemblies enable accurate current sensing with superior insulation and thermal stability in demanding power applications.
Technical Specifications
Parameter | Specification |
Material | Resistance Alloy (Cu-Mn-Ni), Overmolded Thermoplastic |
Current Rating | 100 A to 1000 A |
Voltage Drop | 50 / 75 / 100 mV |
Resistance | 50 µΩ to 500 µΩ |
Temperature Range | -40°C to 125°C |
Insulation Resistance | >10⁶ Ω |
Dielectric Strength | 3000 V AC (1 min) |
Accuracy Class | 0.5% – 1.0% |
Overload Capacity | 120% rated current (30 mins) |
Mounting | PCB / Panel Mount |
Connection Type | Screw, Plug-in, Solder |
Protection Rating | IP67 |
Flame Rating | UL94 V-0 |
Compliance | RoHS, REACH, UL Listed |
Key Features
High Current Capacity
Available in ratings from 100 A to 1000 A.
Durable Construction
Overmolded with thermoplastics like PEI, PPS, PBT, and more.
Precise Sensing
Voltage drops of 50 mV, 75 mV, or 100 mV with resistance from 50–250 µΩ.
Automotive-Grade
Designed for EVs, energy systems, and industrial applications.
Advanced Welding
Electron beam welded or full resistance alloy options.
Applications
1
Electric Vehicles (EVs)
2
Hybrid Vehicles
3
Battery Management Systems (BMS)
4
Energy Storage Systems
5
Charging Infrastructure
6
Industrial Power Distribution
7
Aerospace & Defense Systems
Trust Reliability & Quality
With over 60 years of manufacturing excellence, PML delivers wire assemblies trusted by OEMs and Tier 1 suppliers across sectors demanding robust performance.
ISO 45001
Occupational Health and Safety (OH&S) management systems
ISO 14001
Environmental Management Systems (EMS)
ISO 9001
Quality Management Systems (QMS)
IATF 16949
International Standard for Automotive Management Systems
AS 9100
Aerospace Quality Management System (QMS)
Frequently Asked Questions
Overmolded Shunt Assemblies are current sensing components that use a low-resistance shunt element encased in thermoplastic to measure electrical current accurately while providing insulation and mechanical protection.
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