InsulVolt® PRODUCT
Advanced Silicone Overmolding for Mission-Critical Electrification
High‑Dielectric LSR Overmolding for Next‑Generation Electrification
CK Composites provides vacuum-assisted silicone overmolding for high-voltage insulation components as part of a disciplined domestic manufacturing platform built for electrification and defense infrastructure. Our silicone capabilities sit alongside cast epoxy, filament winding, and laminated systems to support long-lifecycle OEM platforms in transformers, switchgear, rail, data centers, and defense systems.
Engineered for Mission‑Critical Electrification Platforms
The SVT liquid silicone rubber line is purpose‑built for high‑dielectric insulation components embedded in long‑lifecycle electrification and defense platforms. Precision vacuum overmolding produces void‑free, arc‑resistant silicone barriers that control electric fields, manage mechanical stress, and protect cast epoxy structures from cracking and moisture ingress over decades of service.
Key performance advantages:
High‑dielectric LSR formulations for demanding high‑voltage insulation duty
Vacuum‑degassed, void‑free silicone for improved arc resistance and long service life
Tight dimensional control and consistent cure for reproducible electrical properties
Elastic, hydrophobic silicone that relieves mechanical stress and resists tracking and moisture
Domestic Supply Chain
Made in the USA
LSR Overmolding
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Disciplined, Vacuum‑Assisted LSR Overmolding at Scale
CK Composites combines vacuum‑assisted liquid silicone rubber overmolding with digital process monitoring to deliver traceable, repeatable high‑dielectric components within a structured, flow‑based production platform.
The system supports composite, metallic, and epoxy insert overmolding, enabling fully integrated insulation assemblies within a vertically controlled U.S. manufacturing platform rather than fragmented, high‑mix job‑shop work.
Process and material highlights:
Vacuum‑assisted LSR overmolding for precision dielectric encapsulation
High‑purity, platinum‑catalyzed LSR (e.g., Wacker PowerSil XLR 630 or equivalent) for high dielectric strength and low compression set
Deep vacuum capability around 10 mbar for void‑free molding of critical insulation interfaces
Configurable molds and multi‑cavity tools for complex geometries and production scalability
Digital data logging and process traceability for every production run
Integrated into the Cast. Wind. Press. Infrastructure Platform
Advanced silicone overmolding is designed to complement CK Composites’ InsulVolt cast epoxy portfolio as part of our integrated Cast. Wind. Press. architecture for electrification infrastructure. Overmolded silicone shields cast epoxy components from mechanical strain and environmental exposure, enhancing reliability in transformers, switchgear, and other high‑voltage assets that must perform for decades.
Typical assemblies and interfaces:
Overmolded composite or epoxy subassemblies for transformers and switchgear
Silicone barriers and seals that protect cast resin parts from delamination and moisture ingress
Combined silicone‑epoxy insulation systems for compact, high‑power electrification equipment
Mission‑Critical Applications in AI, Grid, and Defense Infrastructure
The advanced silicone overmolding line targets OEMs and utilities building next‑generation AI data centers, grid modernization projects, defense systems, and transportation and industrial electrification platforms. High‑dielectric, vacuum‑treated LSR components support compact, high‑power designs while meeting stringent reliability expectations in these mission‑critical, long‑lifecycle environments.
Component types and use cases:
Vacuum interrupter housings for medium‑ and high‑voltage switching equipment
Insulation boots and connector seals for AI data center power distribution and high‑current bus systems
Bushing and arrester skirts that manage creepage distance and surface tracking in outdoor substations
Encapsulated barrier components that isolate phases and protect sensitive assemblies
Custom‑engineered silicone overmolds around metallic or epoxy cores for specialized electrification and defense platforms within long‑term OEM programs
Disciplined Domestic Supply for Reshored Electrification
All advanced silicone overmolding production is U.S.‑based, providing OEM and utility customers with a disciplined domestic source of high‑dielectric LSR insulation components that aligns with reshoring and infrastructure security priorities. Vertical integration with InsulVolt cast and molded epoxy products shortens lead times, strengthens supply chain resilience, and reduces dependence on fragile overseas capacity.
Why OEMs and utilities partner with CK Composites
Fully domestic, traceable production within a disciplined manufacturing platform for mission‑critical electrical insulation components
Faster, more predictable support for AI, grid, and electrification project timelines through repeatable, flow‑based production rather than ad‑hoc job‑shop capacity
Deep experience in cast epoxy and composite insulation systems, now extended with advanced LSR overmolding
Collaborative engineering support to design optimized silicone overmolded components for specific electrical environments
From Job Shop to Disciplined Domestic Electrification Platform
Built for Today’s Electrification and Defense Demands
CK Composites has rebuilt its operations from a high‑mix job shop into a focused, flow‑based manufacturing platform aligned with electrification and defense infrastructure. Our engineers and technicians now concentrate on mission‑critical insulation components where long‑term reliability, scalability, and disciplined process control matter most.
Made in the USA
We manufacture in the United States as a deliberate commitment to resilient domestic infrastructure. Our focus is electrification, defense, and critical industrial systems that require durable, scalable U.S.‑based capacity.
Quality Assurance
Quality assurance is built into standardized, repeatable processes, from controlled raw‑material qualification to in‑process inspection and testing. Traceable records support long‑lifecycle electrification and defense platforms.
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Precision Machining
Our precision machining and assembly support the broader Cast. Wind. Press. architecture, enabling complete insulation assemblies from one disciplined platform. Coordinated machining, molding, and winding reduce fragmentation and strengthen supply continuity.
InsulVolt® PRODUCT
Partner With CK Composites’ Domestic Electrification Platform for Advanced Silicone Overmolding Solutions
To discuss advanced silicone overmolding solutions for your high‑voltage or high‑dielectric application, connect with the CK Composites engineering team. Our specialists can help you specify silicone overmolded InsulVolt systems that improve reliability, accelerate deployment, and strengthen your domestic supply chain for long‑lifecycle electrification and defense programs.