Durable and Precision-Engineered Stamped Aluminium Compression Lugs Connectors
Our stamped aluminium compression lugs connectors are crafted for reliable electrical connections, ensuring superior conductivity, durability, and ease of installation.
Precision-crafted stamped aluminium compression lugs connectors designed for efficient and reliable electrical connections in diverse industrial applications.
Conex manufactures stamped aluminium compression lugs and cable connectors for dependable, low-resistance electrical terminations. Formed from high-purity aluminium, each lug combines a crimp barrel with a precision-pierced twin-hole palm for secure installation on busbars, switchgear, electrical panels, transformers and power-distribution equipment.
Available in custom conductor sizes, palm dimensions, hole patterns and finishes, our aluminium compression terminals deliver excellent conductivity, corrosion resistance and consistent mechanical strength. Share your drawing, material grade, finish and quantity for a fast manufacturing review and quotation.
Typical Stamped Aluminium Lug Sizes and Stud-Hole Chart
The following manufacturing range is a practical guide for quotation. Final barrel dimensions, stud-hole diameter, hole pitch, palm width and thickness are confirmed against the conductor, crimping die and customer drawing.
| Conductor size (mm²) | Typical stud-hole options | Typical application |
|---|---|---|
| 16–35 | M6, M8 | Control panels and compact terminals |
| 50–95 | M8, M10 | Industrial panels and switchgear |
| 120–185 | M10, M12 | Transformer and busbar connections |
| 240–400 | M12, M16 | High-current distribution equipment |
| 500–630 | M16, M20 | Large transformer and power connections |
Typical range only. Intermediate, imperial and custom sizes, single-hole, two-hole and multi-hole palms are available to drawing.
Stamped Aluminium Transformer Lugs and Stud Connectors
Conex manufactures stamped aluminium transformer lugs and aluminium stud connectors for transformer bushings, busbars, switchgear and power-distribution assemblies. Parts can be produced for conductor sizes from 16 to 630 mm² with M6 to M20 stud holes, custom hole pitch and single-, two- or multi-hole palms. Material grades can be specified as electrical-grade AA 1350, EN AW-1050A, AA 1060, AA 1070 or AA 1100, with bare or tin-plated finishes selected to suit conductivity, corrosion-resistance and installation requirements.
They are cable lugs, butt connectors and reducers formed from high-purity aluminium tube or sheet by stamping, flattening and piercing. The barrel is crimped onto an aluminium conductor with a hydraulic tool, and the palm is bolted to equipment terminals or busbars.
Lugs are made from EC-grade / 1350 or 1060 aluminium with purity of 99.5% or higher. This gives conductivity close to the conductor itself and the ductility needed to crimp without cracking.
Stamped lugs are produced for aluminium conductors from 10 mm² up to 630 mm² (approximately #6 AWG to 1250 kcmil), with palm holes for M6 to M20 or 1/4 in to 3/4 in bolts.
Lugs are designed and tested to IEC 61238-1 (compression connectors for power cables), DIN 46329, BS 4579 and UL 486A-486B, as well as utility specifications.
Stamped lugs are formed from tube, so they have a uniform, dense wall and are very economical in volume. Machined lugs from bar suit special palm shapes and low volumes; cast lugs suit complex shapes but may contain porosity.
The barrel is filled with an oxide-inhibiting compound containing abrasive particles. During crimping it breaks the aluminium oxide film on the strands and seals the joint from moisture, keeping contact resistance low.
Tin plating is recommended when the lug palm will connect to copper busbars or copper terminals, and in humid or corrosive environments, to prevent galvanic corrosion and stabilise contact resistance.
Hydraulic crimping tools with hexagonal or deep-indent dies matched to the lug size are used. The die code and number of crimps marked on the lug must be followed to achieve IEC 61238-1 performance.
Testing includes tensile pull-out of crimped samples, electrical resistance, heat-cycle ageing and short-circuit tests per IEC 61238-1, plus routine dimensional and plating thickness checks.
Yes. We produce custom palm widths, hole spacings, angled palms (45° and 90°), long barrels and markings to customer drawings or utility specifications.
Yes. With sealed end caps, inhibitor compound and heat-shrink insulation, stamped aluminium lugs are widely used outdoors on overhead and underground distribution systems.
Each lug can be marked with conductor size, bolt hole size, die code and manufacturer identification for correct installation and traceability.
MOQ is 10 pieces for sampling. Stamping is most economical at volume, and we can hold stock for scheduled call-offs.
Samples are generally available within 2–3 weeks and production orders within 4–6 weeks, depending on size range, plating and quantity.
Please provide conductor size and class, palm hole size and number of holes, plating requirement, applicable standard and quantity per size.
Need Stamped Aluminium Compression Lugs Connectors? Get a Fast, Detailed Quotation
Send your drawing (STEP, IGES, DWG, DXF or PDF) with material grade, finish and quantity. Our engineers reply with a DFM review, price and lead time. MOQ 10 pcs • ISO 9001:2015 • Exports to USA, UK, Europe, Canada & Australia.
