Component overmolding in electronics - the solution for demanding applications.
As power density increases, designs become more compact, and switching frequencies rise, thermal loads in small assemblies are reaching new levels. Without precise temperature monitoring, performance, efficiency, and long-term reliability can suffer significantly. In demanding applications such as power electronics, e-mobility, automation, and high-performance computing, accurate thermal management is essential to detect critical conditions early, protect sensitive components, and ensure lasting system performance.
Developed as a collaboration between iST and Plastformance, an innovative solution brings sensor and measuring point together in an injection-molded, highly thermally conductive yet electrically insulating plastic. The result is a smart integration concept that delivers excellent thermal coupling, reliable electrical insulation, and strong mechanical stability—all in one compact assembly.
High-performance temperature sensing for demanding applications
The challenge
As power densities continue to rise, more heat is generated in increasingly compact assemblies. Conventional sensing solutions often struggle with poor thermal coupling, leading to inaccurate readings and delayed response times. The result: temperature monitoring that falls short when precision, speed, and reliability matter most.
The solution: Cable lug for EV charging connector
With two-component assembly injection molding using thermally conductive material, the sensor is integrated directly at the measurement point for superior thermal performance. A thermally conductive plastic ensures excellent heat transfer, while integrated electrical insulation provides safety and reliability. An additional outer layer delivers thermal insulation from the surrounding environment, enabling stable and accurate measurement even under demanding operating conditions.
Benefits & characteristics
Maximum Performance
- Fast response times for real-time temperature detection
- Minimal temperature gradients for more accurate readings
- Enhanced measurement precision for greater system reliability
Design Freedom & Easy Integration
- Sensor placement close to live components
- High flexibility for customized designs
- Compact, robust construction for demanding environments
- Simple and reliable assembly
- Easy servicing and replacement thanks to separate sensor and connection technology
Technology highlights
This innovative solution combines three essential functions in one integrated concept
- Efficient thermal coupling
- Reliable electrical insulation
- Robust mechanical protection
By embedding the sensor directly into the component, the technology enables a new level of performance, integration, and reliability—making it ideal for high-performance applications.
Efficient, scalable production
Designed for cost-efficient series production, this solution supports fully automatable manufacturing processes while ensuring reproducible quality at every scale.
Let's talk!
Contact us by e-mail or phone, and our internal sales team will assign you to the internal specialist.
