InsulVolt® PRODUCT
Advanced Silicone Overmolding for High‑Voltage Insulation
High‑Dielectric LSR Overmolding for Next‑Generation Electrification
CK Composites’ advanced silicone overmolding line uses high‑dielectric liquid silicone rubber LSR to produce vacuum‑treated insulation components for demanding high‑voltage applications. This new capability expands the Insulvolt cast and molded epoxy portfolio with tightly controlled, U.S.‑manufactured silicone housings, boots, and encapsulations for AI, grid, and electrification infrastructure.
Engineered for High‑Voltage, Mission‑Critical Performance
The SVT liquid silicone rubber line is purpose‑built for high‑dielectric insulation parts that must perform reliably in harsh electrical environments. 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.
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
Advanced LSR Overmolding Technology
CK Composites combines vacuum‑assisted liquid silicone rubber overmolding with digital process monitoring to deliver traceable, repeatable high‑dielectric parts. The system supports composite, metallic, and epoxy insert overmolding, enabling fully integrated insulation assemblies within one vertically controlled process.
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 with InsulVolt Cast and Molded Epoxy Systems
Advanced silicone overmolding is designed to complement CK Composites’ Insulvolt cast epoxy resin portfolio, creating integrated hybrid insulation systems. Overmolded silicone shields cast epoxy components from mechanical strain and environmental exposure, enhancing reliability in transformers, switchgear, and other high‑voltage assets.
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
Typical Applications in AI, Grid, and Electrification Markets
The advanced silicone overmolding line targets OEMs and utilities building next‑generation AI data centers, grid modernization projects, and transportation and industrial electrification systems. High‑dielectric, vacuum‑treated LSR components support compact, high‑power designs while meeting stringent reliability expectations in these mission‑critical 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 platform
Domestic Supply Chain, Faster Lead Times
All advanced silicone overmolding production is U.S.‑based, giving OEM and utility customers a secure, domestic source of high‑dielectric LSR insulation components. Vertical integration with InsulVolt cast and molded epoxy products shortens lead times, strengthens supply chain resilience, and reduces dependence on overseas suppliers.
Why OEMs and utilities partner with CK Composites
Fully domestic, traceable production of mission‑critical electrical insulation components
Faster response to urgent AI, grid, and electrification project timelines
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
InsulVolt® PRODUCT
Partner With CK Composites 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.
WHY CHOOSE CK COMPOSTIES
Over 65 Years of Experience
At CK Composites, our engineers and technicians are able to help customers in a wide range of industries solve problem applications using our line of custom composite solutions.
Made in the USA
Since the 1950's, we have been supporting the electrical, oil and gas, medical, defense, transportation and waste water industries with proven, innovative composites and engineering solutions.
Quality Assurance
Quality assurance procedures include testing and inspection of incoming raw materials, in-process inspection and both destructive and non-destructive material testing.
Precision Machining
We have a complete machine shop with precision milling, routing, turning and assembly capabilities. We ensure efficiently produce parts with the proper fit and finish required.