ABOUT ESTAR

Shijiazhuang Estar New Energy specializes in high-voltage DC contactors for EV chargers, energy storage, and telecom systems. Founded in 2013, our Wuxi-based factory has over 180 staff and advanced production lines. We serve 200+ global partners with certified products (CE, TUV, UL, CCC), focusing on quality, innovation, and sustainability.

2013

Year of Foundation

180+

Staffs

200+

Overseas Partners

High-Voltage DC Contactor Manufacturing Process Overview

To ensure the reliability and safety of high-voltage DC contactors in critical applications such as new energy vehicles and energy storage systems, every step of the manufacturing process must be strictly controlled. From metal forming to performance testing, each procedure reflects a commitment to precision and quality.

Precision Metal Forming

Using molds to press iron components into the core structure of the contactor housing, ensuring mechanical strength and dimensional consistency.
Insulation Potting Process

Filling key areas with insulating gel to enhance dielectric strength and environmental resistance, preventing arcing from damaging internal components.
Air Bubble Removal

After potting, vacuum or manual operations are used to remove residual air bubbles, ensuring product sealing and stable electrical performance.
Curing & Heat Treatment

Cured through controlled heating to solidify the gel, forming a stable structure that improves heat resistance and mechanical strength.
Terminal Shaping and Cutting

Copper terminals or busbars are trimmed and polished to ensure smooth connections, free of burrs, and with good electrical contact.
Final Performance Testing

Key parameters such as dielectric strength, switching capability, temperature rise, and electrical lifespan are tested to ensure each contactor meets quality standards.

Why choose ESTAR?

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Service Excellence

We provide responsive, multilingual customer service and technical support across the entire project lifecycle. From pre-sales consultation to after-sales troubleshooting, our team ensures every client receives timely and effective assistance.
Reliable Quality

Every product goes through 100% testing before delivery. Our factory is ISO9001 certified and all major product lines are CE, TUV, or UL approved. We never compromise on quality.
Professional Team

Our experienced R&D and production teams are the backbone of our innovation. With over 50 engineers and a rigorous quality control department, we continuously develop reliable and high-performance DC contactor and power module products.
Global Market Presence

With partners in over 30 countries, we understand the diverse needs of customers worldwide. Whether you’re an EV charging operator in Europe or an energy integrator in Southeast Asia, we have the experience to serve your local market.