Cast Epoxy Resin

InsulVolt® Electrical Cast Epoxy Resin Manufacturer

InsulVolt® cast epoxy components provide electrical insulation, mechanical strength, and environmental durability for medium- and high-voltage equipment.

Electrical insulation up to 69kV+

Precision-cast via state-of-the-art APG

Integrated conductors and inserts

Structural and environmental durability

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Rigid. Strong. Precise.

State-of-the-Art Cast Resin Manufacturing

CK Composites combines advanced epoxy resin systems with advanced modern production technologies including Automatic Pressure Gelation (APG), vacuum casting, precision machining, and comprehensive testing. From prototype development through high-volume production, our manufacturing platform delivers the consistency, quality, and throughput required for today’s critical electrical infrastructure.

Key Performance

Dielectric strength up to 400 V/mil. Heat deflection temperatures from 62°C to 165°C across formulations. Compressive strength up to 30,000 psi.

Cast Epoxy Resin Components

InsulVolt® components appear throughout the electrical insulation stack, wherever rigid dielectric performance and structural load-bearing are required in the same part.

Flexible Performance

Versatile Resin Systems

Cast epoxy remains one of the most versatile materials for medium- and high-voltage equipment because it combines dielectric performance, mechanical strength, and design flexibility within a single molded structure.

CK Composites’ InsulVolt® portfolio of cycloaliphatic and Bis-A epoxy resin systems provides the flexibility to tailor electrical, mechanical, and environmental performance characteristics to the specific requirements of each application.

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Strength

Performance

For Next‑generation Insulation Systems

Integrated Cast Resin + Silicone Solutions

Many modern electrical insulation systems require the structural performance of cast epoxy with the insulation and/or stress relieving of silicone. CK Composites brings these technologies together within a single manufacturing platform, helping OEMs simplify supply chains while improving integration, quality, and program execution.

Single-source manufacturing

Reduced supplier complexity

Integrated engineering support

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Full Process, APG-based Production

Process Capabilities & Quality Discipline

Advanced Manufacturing Technology

State-of-the-art production platforms designed to improve process capability, repeatability, and long-term manufacturing performance.

Repeatability & Control

Controlled manufacturing processes designed to deliver dimensional accuracy, part-to-part uniformity, and consistent quality at the source.

Scalable Production

Manufacturing systems built to support qualification, production launch, and sustained OEM demand throughout the product lifecycle.

U.S.‑based Manufacturing & Supply Chain

Our domestic supply chain ensures consistent, reliable production, shorter lead times, and greater responsiveness when challenges arise.

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Representative Applications

Cast epoxy resin is typically specified for primary dielectric and structural roles where dimensional precision, void-free construction, and long service life under electrical load are required.

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High‑Voltage Switchgear

Bushings, support insulators, and phase barriers for AIS, GIS, vacuum breakers, and reclosers — engineered to perform under sustained electrical stress.

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Grid‑scale Power Electronics

Bus supports, CT/PT housings, and dielectric structures for substations and distribution equipment supporting grid modernization and energy transition.

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Medical Imaging Systems

Main tunnels, tubes, and other components designed to meet modern healthcare’s stringent standards.

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Power Transformers

Coil encapsulation, insulation barriers, and tap changer components for dry-type, liquid-filled, and specialty transformer platforms where thermal and dielectric stability must hold for decades

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Defense

Cast epoxy structural components for defense platforms requiring domestic origin, dimensional repeatability, and long-term environmental durability.

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Data Centers

High-dielectric insulation components for the switchgear and distribution equipment that power next-generation data center infrastructure.

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Custom Cast Epoxy Resin Components

Design & Engineering Support

Successful insulation components are built at the intersection of material science, manufacturing expertise, and application knowledge. CK Composites’ engineering team works closely with OEMs to navigate these considerations, helping optimize material selection, component design, manufacturability, and long-term performance for demanding electrical applications.

Looking for a disciplined U.S. manufacturing partner?

Let’s match materials to systems that meet your application needs.

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