Process Capabilities

Manufacturing Platforms Built for Mission-Critical Components

Electrification, data centers, defense modernization, and infrastructure investment are driving demand at a scale few supply chains were built to support. CK Composites combines decades of manufacturing expertise with modern production platforms designed to support qualification, production launch, and long-term OEM demand.

The result? Manufacturing systems built for consistency, scalability, and resilience in mission-critical applications.

How We Build Components

3 Processes Under 1 Roof:
Cast. Wind. Press.

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.

Cast

Precision molding and encapsulation of epoxy and silicone.

Wind

Wound FRP architectures for lightweight, high-strength structures.

Press

Densified laminates manufactured through carefully controlled resin impregnation and lamination

Integrate

Combining materials, manufacturing processes, and engineering expertise into complete components

Casting / APG

InsulVolt® Cast Epoxy Manufacturing

CK combines advanced epoxy resin systems with advanced modern production technologies, including APG, vacuum casting, precision machining, and comprehensive testing.

Core Process Modes:

  • Vacuum material preparation
  • Automated pressure gelation
  • Embedded conductor integration
  • Controlled cure cycles
  • Dielectric testing and verification

Best Used For:

  • Bushings
  • Vacuum interrupter housings
  • Loadbreak switches
  • Instrument transformer components
  • Structural electrical insulation

Custom Capabilities:

  • Embedded conductors
  • Complex geometries
  • Multi-cavity tooling
  • Application-specific resin systems

Filament Winding

InsulWynd® Fiberglass Filament Winding

Filament winding uses continuous fiber reinforcement placed in controlled patterns to create lightweight structures with highly engineered mechanical properties.

Core Process Modes:

  • Controlled fiber placement
  • Resin impregnation
  • Automated winding patterns
  • Precision curing

Best Used For:

  • Radomes
  • Pressure vessels
  • MRI tunnels
  • Structural composite assemblies

Custom Capabilities:

  • Tailored reinforcement architecture
  • MRI-compatible systems
  • Cryogenic applications
  • RF-transparent structures

Laminating / Pressing

InsuLam® Laminated Densified Wood

Densified laminate materials are manufactured through a vertically integrated process spanning veneer preparation, resin treatment, lamination, densification, machining, and finishing. CK uniquely produces these components through a fully integrated process—from veneer preparation through finished machining—within a single U.S. facility.

Core Process Modes:

  • Veneer preparation
  • Resin impregnation
  • High-pressure lamination
  • Precision machining

Best Used For:

  • Transformer pressure rings
  • Coil supports
  • Railcar shoe beams
  • Structural insulation systems

Custom Capabilities:

  • Multiple laminate grades
  • Grain orientation optimization
  • Large-format structures
  • Finished-machined assemblies

Silicone Injection / Overmolding

Liquid Silicone Rubber (LSR) Overmolding Systems

Liquid Silicone Rubber (LSR) overmolding combines dielectric insulation, environmental sealing, and mechanical compliance in a single component or assembly. LSR components can function as standalone insulating elements or as part of integrated cast epoxy + silicone insulation systems.

Core Process Modes:

  • Precision silicone molding
  • Vacuum-assisted processing
  • Integrated assembly molding
  • Controlled cure systems

Best Used For:

  • Vacuum interrupter assemblies
  • Conductor interfaces
  • Environmental sealing systems
  • Integrated insulation assemblies

Custom Capabilities:

  • Epoxy + silicone integration
  • Mechanical stress relief systems
  • Custom tooling
  • Application-specific formulations

For Next‑generation, Mission-Critical Systems

Where Materials, Engineering & Manufacturing Converge

CK Composites’ engineering and manufacturing teams collaborate to optimize composite solutions composite solutions that leverage our material science, manufacturing expertise, and application knowledge. This integrated approach improves quality, accelerates qualification, reduces risk, and supports long-term production programs.

Application-driven material selection

Designs optimized for manufacturing and scalability

Earlier identification of technical and production risks

Looking for a disciplined U.S. manufacturing partner?

Launch your next high‑voltage build with CK Composites’ cast, wind, and press capabilities by starting with our engineering team today.

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