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We offer a comprehensive portfolio including resistors, braking units, reactors, power filters, and transformers, with full customization options to meet diverse application requirements.
DUFEW Ultra-Thin Aluminum Clad Resistor is designed for industrial applications where installation space is limited but reliable power dissipation is essential. Featuring an ultra-slim aluminum housing and a fully enclosed construction, it offers efficient heat dissipation, excellent environmental protection, and stable performance for dynamic braking, servo drives, VFDs, load banks, and power control systems.
Available in power ratings from 50W to 6kW, resistance values from 0.01Ω to 120kΩ, and operating voltages up to 1200V, the resistor supports OEM and ODM customization to meet various industrial requirements.
The resistor is manufactured with precision-wound nickel-chromium (Ni-Cr) or constantan resistance wire insulated by mica layers and completely encapsulated inside an aluminum alloy housing using a flame-retardant, high-insulation potting compound. This enclosed construction improves heat transfer while protecting the resistance element from dust, moisture, oxidation, and vibration.
Its ultra-thin profile, with a minimum thickness of only 6--8 mm, allows direct installation in compact electrical equipment where conventional aluminum housed resistors cannot fit. Multiple terminal styles, mounting options, and electrical specifications are available for different application requirements.
| Model Code | Description |
|---|---|
| CAR | Ultra-Thin Aluminum Clad Resistor |
| 1500W | Rated Power |
| 27R | Rated Resistance |
| J | Resistance Tolerance (J=±5%, K=±10%, H=±3%) |
| Parameter | Specification |
|---|---|
| Power Range | 50W--6kW |
| Operating Voltage | ≤1200V |
| Resistance Range | 0.01Ω--120kΩ |
| Resistance Tolerance | ±3% / ±5% / ±10% |
| Protection Rating | IP00 |
| Temperature Coefficient (TCR) | ≤300 ppm/°C |
| Flame Retardant Rating | UL 94V-2 |
| Standard | GB/T 5792 |
Choosing the right power resistor means more than selecting resistance and power ratings. DUFEW focuses on delivering reliable thermal performance, consistent manufacturing quality, and flexible customization for industrial applications worldwide.
The ultra-thin aluminum housing, with a minimum thickness of only 6--8 mm, allows multiple units to be mounted side by side, making it ideal for compact control cabinets, servo drives, and VFD systems.
Every resistor is manufactured using precision resistance wire winding, high-quality insulating materials, automated production processes, and strict quality inspection to ensure consistent electrical performance and long service life.
DUFEW supports customized resistance values, power ratings, housing dimensions, terminal configurations, lead wire options, mounting structures, and low-inductance designs according to customer drawings or technical specifications.
With years of experience in industrial power resistor manufacturing, DUFEW supplies reliable solutions for automation equipment manufacturers, system integrators, distributors, and OEM customers worldwide.
The compact aluminum alloy enclosure is only 6--8 mm thick, helping maximize installation space inside electrical cabinets and compact industrial equipment.
A high-insulation flame-retardant potting compound completely seals the resistance element, providing excellent resistance to dust, moisture, vibration, and oxidation.
The aluminum housing and thermally conductive filling material quickly transfer heat to the mounting surface or heat sink, improving cooling efficiency and power density.
Available with terminal or lead wire connections, the resistor can be customized in resistance value, power rating, dimensions, and mounting style to suit different applications.
With a profile as thin as 6--8 mm, the resistor fits easily into compact control cabinets, servo systems, and VFDs, allowing higher installation density without sacrificing performance.
The sealed aluminum housing and flame-retardant potting compound effectively protect the internal resistance element from dust, moisture, oxidation, and vibration, improving long-term reliability.
The aluminum enclosure acts as an efficient heat sink, rapidly transferring heat away from the resistance element. When mounted to a metal plate or external heat sink, thermal performance is further enhanced.
Designed to deliver high power output in a compact package, making it ideal for applications where installation space is limited but reliable energy dissipation is required.
Available from 0.01Ω to 120kΩ, with resistance tolerances of ±3%, ±5%, and ±10%, covering both low-resistance braking and high-resistance load applications.
DUFEW provides OEM and ODM services, including customized dimensions, resistance values, power ratings, terminal styles, lead wires, mounting configurations, and low-inductance designs.
Unlike conventional open-type resistors, the Ultra-Thin Aluminum Clad Resistor is designed for compact electrical systems requiring efficient thermal management and reliable environmental protection.
Ideal for regenerative braking circuits in compact servo systems where installation space is limited.
Used for dynamic braking, energy dissipation, and voltage stabilization in industrial inverter systems.
Suitable for battery charge/discharge equipment, pre-charge circuits, and energy dissipation applications.
Provides stable resistive loads for power supplies, battery testing, industrial testing equipment, and electronic load systems.
Widely used in PLC control cabinets, automation systems, robotics, CNC equipment, and compact electrical control panels.
| Characteristic | Test Conditions | Performance |
|---|---|---|
| Dielectric Withstand Voltage | 2500VAC / 50Hz / 60s | Leakage Current ≤10mA |
| Insulation Resistance | 1000VDC | ≥100MΩ |
| Short-Time Overload | 10× Rated Power for 5s | No Visible Damage |
| Load Life | Cyclic Operation (10s ON / 90s OFF) | ＞9,000 Hours |
| Damp Heat Resistance | 40°C ±2°C, 90--95% RH, 100h | ΔR ≤ ±(1%R + 0.05Ω) |
| Rapid Temperature Cycling | -55°C / 55°C / 155°C, 15 min each, 5 Cycles | ΔR ≤ ±(2%R + 0.05Ω) |
| Heat Resistance | 350°C / 2h | No Visible Damage or Discoloration |
| Temperature Coefficient (TCR) | Rated vs. Initial Resistance | ＜300 ppm/°C |
| Flame Resistance | 10× Rated Power for 5 min | No Ignition |
| Characteristic | Test Conditions | Performance |
|---|---|---|
| Terminal Strength | 45N / 30s | No Loosening or Visible Damage |
| Vibration Resistance | 5--200Hz, 1g, 98m/s² | No Structural Damage |
| Resistance to Soldering Heat | 350±5°C Solder, 3s | ΔR ≤ ±(1%R + 0.05Ω) |
| Appearance | Visual Inspection | No Visible Damage, Clear Marking |
| Solderability | 235±5°C Solder, 5s | Solder Coverage ≥95% |
| Comparison Item | DUFEW Ultra-Thin Aluminum Clad Resistor | Conventional Power Resistor |
|---|---|---|
| Housing Design | Ultra-thin aluminum housing with fully enclosed potting | Mostly open or semi-enclosed construction |
| Installation Space | Slim 6--8 mm profile allows compact side-by-side installation | Larger housing requires more installation space |
| Environmental Protection | Better resistance to dust, moisture, vibration, and oxidation | Limited environmental protection for harsh conditions |
| Heat Dissipation | Aluminum housing supports direct chassis or heat sink mounting for improved cooling | Primarily relies on natural air cooling |
| Resistance Range | Wide range from 0.01Ω to 120kΩ | Typically limited resistance range depending on construction |
| Application | Compact industrial equipment, VFDs, servo systems, battery equipment, and load testing | General-purpose power dissipation applications |
| Customization | Supports customized dimensions, terminals, lead wires, power ratings, and resistance values | Limited customization |
A: Its main advantage is the ultra-thin structure, with a thickness of only 6--8 mm. This compact design provides efficient power dissipation while reducing installation space, making it suitable for servo drives, VFD systems, battery equipment, and industrial control cabinets where space is limited.
A: Yes. The flat aluminum base allows direct mounting onto a metal chassis or external heat sink. Applying thermal grease between the contact surfaces can further improve heat transfer efficiency and support higher continuous operating performance.
A: The fully enclosed aluminum housing combined with flame-retardant insulating potting provides effective protection against dust, moisture, vibration, and oxidation. Compared with open resistor structures, this design offers better environmental adaptability, while additional enclosure protection can be added for outdoor or high-protection applications.
A: Yes. DUFEW provides OEM and ODM customization based on specific electrical, mechanical, and installation requirements. Custom options include resistance value, power rating, housing dimensions, terminal and lead wire configuration, mounting structure, low-inductance design, and other special specifications. Customers can provide drawings or technical requirements, and DUFEW engineers will evaluate and develop a suitable solution.
A: They are commonly used in applications requiring compact size and reliable heat dissipation, including servo drive systems, variable frequency drives, dynamic braking circuits, battery charge and discharge equipment, industrial automation systems, power supplies, electronic load systems, and renewable energy equipment.
DUFEW provides OEM and ODM manufacturing services for industrial power resistor applications, supporting equipment manufacturers, distributors, and system integrators with customized solutions covering electrical performance, mechanical structure, and installation requirements.
Customization capabilities include power ratings from 50W to 6kW, resistance values from 0.01Ω to 120kΩ, housing dimensions, terminal and lead wire configurations, mounting structures, low-inductance designs, custom labels, logos, and application-specific modifications.
Each customized product is developed through engineering evaluation and manufacturing control to ensure reliable thermal performance, electrical stability, and long-term operation in industrial environments.
Selecting the correct resistor helps maximize system reliability and service life. When choosing a model, consider the following factors:
| Selection Item | Recommendation |
|---|---|
| Power Rating | Choose according to continuous or intermittent duty cycle with sufficient safety margin. |
| Resistance Value | Match the requirements of the inverter, servo drive, or electrical circuit. |
| Operating Voltage | Ensure the maximum working voltage does not exceed the product specification. |
| Cooling Method | For higher power applications, mount the resistor on a metal plate or heat sink. |
| Installation Space | Select dimensions based on the available cabinet or equipment space. |
| Connection Type | Choose between terminal or lead wire configurations according to installation requirements. |
If you are unsure which model best fits your application, DUFEW's engineering team can recommend the most suitable solution based on your operating conditions.
- Professional manufacturer of industrial power resistors and braking solutions
- Stable product quality with strict manufacturing and quality control
- Flexible OEM & ODM services for global equipment manufacturers
- Fast response for technical support and project evaluation
- Reliable delivery for standard and customized products
- Complete product portfolio covering wirewound, corrugated, tubular, aluminum housed, braking, and customized power resistors
Looking for a reliable Ultra-Thin Aluminum Clad Resistor supplier?
DUFEW provides standard products and customized solutions for industrial automation, renewable energy, motor drives, testing equipment, and power electronics.
Contact our engineering team today for:
- Product recommendations
- Technical consultation
- OEM & ODM support
- Sample requests
- Competitive quotations
DUFEW -- Your Trusted Industrial Power Resistor Manufacturer in China.
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No. 364, Kangyang Road, Huangdai Town, Xiangcheng District, Suzhou City, Jiangsu Province, China
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