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Customized HV/MV Products

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Everything inside transmission and distribution equipment needs insulating, and not all of it fits a product family. This page is for the parts that do not. The odd shape, the tight envelope, the interface that has to match something you already have.

Indisol casts those parts in epoxy resin, to your specification. Because the part is moulded rather than fired or machined, the geometry is yours: ribs, creepage profiles, mounting features and fixing centres come out in one piece, and metal inserts, electrodes or conductors are encapsulated inside the resin instead of bolted on afterwards.

That covers low, medium, high and very high voltage, indoors and outdoors, and the special cases — SF6 and other dielectric fluids, high humidity, coastal and polluted environments.

New performance, safety and environmental requirements keep producing parts that no catalogue answers. Those are the ones worth sending us.

Custom cast epoxy product for medium and high voltage, Indisol

Custom cast epoxy parts for medium and high voltage

50 kg & 1 m+Down to small intricate parts

29Clamping machines, plus a mixing line

2 000 t/yearEpoxy processing capacity

LV to VHVVoltage classes we cast for

What we already cast to order

Three recurring shapes, to give a sense of the range. None of them is a catalogue item — each one was engineered to a customer specification.

SwitchgearEpoxy housingsCast resin enclosures for switches in medium voltage equipment, used in substations and transformer stations. Cast to almost any shape and size, which is why they suit tailored solutions.

TransformersBushing plates and terminalsRound or square resin plates, threaded with bolts or cables, that manage and distribute voltage in instrument transformers and oil-filled transformers. High voltage versions exist for HV equipment.

Anything elseMetal encapsulated in resinWhere a part has to be one monolithic piece instead of an assembly — inserts, electrodes and conductors cast in, with no fasteners sitting in the insulating path.

How a custom part comes about

You do not need a finished design to start the conversation. You need to know the duty.

01Send the dutySystem voltage, mechanical load, service environment, and the interfaces the part has to meet. A drawing or a sketch if you have one; a description if you do not.

02Get a design proposalWe come back with a proposal engineered to that specification rather than a catalogue page, including the choice of resin system for the environment.

03PrototypeVacuum or atmospheric pressure casting covers prototypes and small series, so the first parts do not wait for series tooling.

04SeriesGelation under pressure at temperature for medium and large series — it is what holds dielectric reliability and dimensional accuracy across a whole run, not just the first pieces.

The resin follows the environment

This is the first thing we will ask, and it is settled by where the part lives rather than by the voltage. Both families cover the whole voltage range.

IndoorsAromatic epoxyBisphenol A-epichlorohydrin resin with an anhydride hardener. Excellent dielectric performance where the surface is protected from weather.

OutdoorsCycloaliphatic epoxyFilled with pre-treated silica. Resists UV, tracking and weathering. Also the choice indoors where there is humidity or pollution.

AggressiveSilicone overmouldedA silicone layer overmoulded on our own line, over the cast part, where the environment demands extra surface protection.

Where neither standard family suits the duty, resin systems can be developed to specific electrical, thermal and mechanical requirements. More on our epoxy resin technology.

Start with a family, if one fits

Many enquiries that arrive here belong to a family we already cast. It is quicker for you to start there. If none of these is your part, keep reading.

Support & post insulatorsHold a conductor away from earth and carry the mechanical load.See the range →

Medium voltage cast epoxy bushing, Indisol

BushingsTake a live conductor through a wall, an enclosure or a tank.See the range →

Cast epoxy components for gas insulated switchgear, Indisol

GIS productsBusbar supports, fuse tubes and breaker chambers inside gas insulated equipment.See the range →

Divider insulatorsInsulate and, at the same time, give a low voltage signal that follows the conductor.See the range →

Medium voltage voltage sensors and indicators in cast epoxy, Indisol

Medium voltage sensorsMeasure voltage or current to a stated accuracy class.See the range →

Third rail insulator supporting a T-section conductor rail, Indisol cast epoxy

Third rail insulatorsHold the conductor rail that powers a metro or light-rail line.See the range →

Customized cast epoxy product for medium and high voltage, Indisol

Custom HV/MV productsEpoxy housings for switches, and shapes none of the above describes.You are here

Common questions

Is there a minimum order?Tell us the quantity with the enquiry and we will answer it honestly for your part. Vacuum and atmospheric casting exist precisely for prototypes and small series.

Can you work from our drawing?Yes, and it is the most useful thing you can send. A sketch of the interfaces is already enough to start.

Can you match an existing part we are replacing?Send the part or its drawing along with the duty it performs. Cast resin lets the geometry follow an existing interface rather than the other way round.

What voltages do you cover?Low, medium, high and very high voltage. Our in-house test capability reaches 200 kV for industrial frequency and partial discharges.

How big can the part be?From pieces above 50 kg and one metre down to small, intricate components, on 29 clamping machines and a continuous mixing line.

Will it be tested?Electrical and mechanical testing runs in house and in external laboratories under ISO 9001 and ISO 14001. For gas insulated applications every single piece is tested, not a sample.

If it has to insulate and nothing off the shelf fits, send it to us.

Every part we cast is engineered to a specification rather than selected from a catalogue, so you get a design proposal back, not a page number. The odd ones are the interesting ones.

Request a quotation → or see how we cast them

Useful to includeThe system voltage, and whether the part sits indoors, outdoors or in gasThe mechanical duty — load, direction, and any deflection limitFixing centres and interfaces, or a drawing if you have oneService temperature, and anything unusual about the environmentQuantity, and whether this is a prototype or a series