This concept offers the most efficient production of EMC filter assy in high volume by multi-functional overmoulded busbars. Due to EMC conformity requirements, the demand for clever designs of EMC Filters is very real. On one hand, the filter function needs to be implemented swiftly – often to heal otherwise non-conforming HV components – while on the other hand the production must be cost-competitve. Key solutions may be selected from Intensa´s „toolbox“, re-configured and carried over to production by overmoulding technology. Overmoulding replaces widely used insulation foils that besides electrical isolation provide the defined air gap width between ferrite and busbars. Additionally, the plastic overmould enables „free of charge“ functions such as heatstaking domes for PCBA. Either spring contacts or solid laser welded joints may be used for the electrical connection of the filter stages towards the (HV) busbars. The overmoulded leadframes substitute costly FPC or wire-harnesses.