Liquid Silicone Rubber (LSR) Overmolding

InsulVolt® Flexible Silicone Overmolding for Sealed, Stress‑Relieved Dielectric Components

Liquid Silicone Rubber (LSR) overmolding extends the InsulVolt® platform by adding flexible dielectric insulation, environmental sealing, and mechanical stress relief to mission-critical electrical components.

High Dielectric Strength

Fully Domestic Supply Chain

Void-Free, Traceable Production

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Durable. Stable. Waterproof.

Silicone–Epoxy Overmolding for One‑Step Sealing, Stress Relief, and Field Control

Liquid Silicone Rubber (LSR) overmolding encapsulates conductors and substrates in a flexible, high-dielectric silicone layer — providing environmental sealing, mechanical stress relief, and dielectric field control in a single operation.

At CK Composites, it’s fully integrated with our cast epoxy platform, enabling combined silicone-epoxy assemblies under one roof.

Key Performance

LSR components can function as standalone insulating elements or as part of integrated cast epoxy + silicone insulation systems.

Flexible Performance

Multipurpose Silicone Roles in High‑Voltage Insulation Systems

CK Composites LSR components serve multiple functions within a high-voltage insulation system — often simultaneously.

Primary Dielectric Insulation

Mechanical Protection & Stress Relief

Environmental Sealing

Dielectric Field Management

Structural Integration

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Sealing

Protection

For Next‑generation Insulation Systems

Integrated LSR Manufacturing Platform

CK Composites uniquely combines Liquid Silicone Rubber (LSR) overmolding and InsulVolt® cast epoxy manufacturing within a single U.S.-based manufacturing platform. Depending on the application, silicone may serve as the primary dielectric interface surrounding energized conductors, while cast epoxy provides the structural insulation and mechanical integrity required for the overall assembly.

By producing both technologies under one roof, CK Composites helps OEMs simplify supplier management, improve design coordination, and strengthen long-term supply chain reliability while supporting increasingly demanding electrification applications.

Traceable, closed‑loop Silicone Overmolding

Process Capabilities & Quality Discipline

Precision LSR Manufacturing

Advanced liquid silicone rubber (LSR) molding systems designed to produce high-performance insulation components with exceptional process control and repeatability.

Repeatability & Control

Controlled manufacturing processes designed to deliver consistent dielectric properties, dimensional accuracy, and quality at the source.

Integrated Epoxy & Silicone Platform

Vertically integrated manufacturing capabilities that combine cast epoxy and silicone overmolding into a single engineered solution.

Testing & Validation

Electrical, mechanical, dimensional, and environmental verification supports customer qualification requirements and long-term production confidence. Material and production traceability are maintained throughout the manufacturing process.

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Representative Applications

Silicone overmolding is typically specified where environmental sealing, dielectric field control, or mechanical flexibility are required alongside structural insulation.

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High‑Voltage Switchgear Insulation

Vacuum interrupter housings and bushing assemblies for AIS, GIS, and vacuum breaker platforms requiring integrated sealing and dielectric performance.
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Grid‑scale Power Electronics

Encapsulated barrier components and arrester skirts for substation and distribution equipment operating in harsh outdoor environments.
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Medical Imaging Systems

High-dielectric fiberglass and silicone assemblies for MRI and other medical platforms requiring non-conductive, dimensionally stable enclosures.
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Defense & Secure Communications

Overmolded components for defense platforms where domestic origin, process traceability, and long-term reliability are non-negotiable.
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Data Center Infrastructure

Insulation components for distribution equipment supporting the power density demands of next-generation data centers.
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Industrial Power Systems

Custom-engineered encapsulated assemblies for industrial applications requiring moisture resistance and electrical isolation under load.
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Custom Silicone Components

Design & Engineering Support

Successful silicone insulation systems are developed at the intersection of material science, manufacturing expertise, and application knowledge. CK Composites partners with OEMs to optimize material selection, component geometry, interface design, manufacturability, and long-term performance for demanding electrical insulation and sealing applications.

Whether developing standalone silicone components, overmolded assemblies, or integrated cast epoxy + silicone insulation systems, CK helps customers transform application requirements into reliable, repeatable manufacturing solutions.

Looking for a disciplined U.S. manufacturing partner?

Let’s engineer silicone and epoxy insulation systems that match your voltage, sealing, and reliability requirements.

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