Case Study: Atom Power accelerates development of UL-ready solid-state circuit breakers with Protolabs' rapid injection molding

Energy startup uses molded prototypes and production parts to revolutionize circuit breaker industry

Atom Power, a Charlotte-based energy startup developing the first commercially viable solid-state circuit breakers for large business and industrial buildings, faced the challenge of moving from in-house 3D-printed prototypes to injection-molded parts while racing to secure Underwriters Laboratories (UL) approval. The company needed design-for-molding expertise, rapid iteration, and low-volume production to avoid large inventories before certification—so it turned to Protolabs for quick-turn, on-demand injection molding and engineering support.

Protolabs supplied injection-molded prototype and end-use parts (including ETPU enclosures and Isoplast 202EZ disconnect components), used its automated design-analysis tools and applications engineers to refine multiple iterations, and delivered parts in as little as 15 days. That support enabled Atom Power to complete UL-required testing—including a 10,000-mechanical-cycle test with no fatigue or stress failures—keep production volumes low during certification, and accelerate rollout of 100A AC/DC models while progressing to 200A and 800A designs.

Atom Power

Taylor Santore

Mechanical Engineer and Project Lead