Energy efficient electrical connections

We offer consulting and training services for maximising the efficiency of high current electrical connections used in primary metal production industries.

The service offers considerable cost savings to energy-intensive industries such as aluminium, zinc and copper smelters.

Setting test conditions on the CSIRO High Amperage Testing Facility. © Mark Fergus

Our expertise

  • specialist engineering design and review— purpose-designed solutions that provide optimal electrical efficiency to solve existing problems
  • process audits—detailed review of existing plant component design and process conditions
  • validation support—identification of improvements that offer the best return
  • specialist technical training – for both operational teams as well as decision makers to improve efficiency of day-to-day plant management.


To help industry partners in the design and testing process, we examine the sophisticated physics involved in the electrical supply infrastructures of large-scale facilities and assess the impact of potential improvements. Modelling and simulation are key tools for future process and design improvement to help our industry partners improve electrical energy efficiency.

We can gain a clear view of power infrastructure’s performance and make informed decisions about potential changes – we can solve fully coupled thermal-electrical-mechanical equations and achieve convergence in highly nonlinear problems, including complex contact scenarios. We can also develop sophisticated modules that clients can apply to their existing in-house systems for future testing.


The high amperage testing facility located in Clayton (Melbourne) conducts full-scale testing of new designs and industrial materials and customises experimental studies to suit each client’s needs.

Installing monitoring probes on client industrial samples ready for testing. © Mark Fergus

Together, our testing facility and modelling can analyse full-scale industrial components offline, causing no interruption to the client’s production. This allows us to generate highly accurate data and insight into the way electricity flows through the components and across electrical contacts.

We can also assess other parameters like the material selected, the impact of operating temperatures and pressures on electricity usage and can determine the most suitable and practical surface preparation and assembly techniques.

The facility gives industry the ability to ‘de-risk’ research and development and technical improvements by testing full- sized components and materials offline and most importantly, under normal operating temperatures, atmosphere and current densities.

Clients include companies from the aluminium, copper, zinc and ferro-alloy production industries.

Use this service

Contact Mr David Molenaar for more information about our services for maximising the efficiency of high current electrical connections used in primary metal production industries.

Mr David Molenaar

Senior Research Consultant · Manufacturing

  • Phone:
    • +61 3 9545 8893

Clayton central precinct

Research Way,

Clayton Vic 3168


Detailed Information


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