We specialize in providing cutting-edge mold and injection molding solutions specifically engineered for the UHV industry. We understand that your components must withstand extreme electrical, mechanical, and environmental stress.
The Challenge: An Unrealized Academic Breakthrough
The ambition was born in the labs of Tsinghua University: to create a new generation of Ultra-High Voltage (UHV) insulation technology. This critical academic challenge, pivotal to China’s “Double Carbon” goals, was later joined by the renowned research teams of Wuhan University and Nanchang University. For years, this powerful consortium theorized and experimented, yet a viable path from concept to a functional, manufacturable product remained elusive. The core challenges—uncontrollable dimensional accuracy, material brittleness, and the lack of a suitable production process—formed a barrier that pure academic research could not overcome.
The Turning Point: Where Theory Met Manufacturing Mastery
Stalled at the final hurdle, Nanchang University invited Livepoint to join the project. They didn’t need another theorist; they needed a partner who could engineer the impossible. Our role was to bridge the critical gap between groundbreaking research and industrial-scale manufacturing.
We analyzed the consortium’s designs and identified the root cause: conventional mold technology and processes were fundamentally inadequate for this application. Our mission was to invent the tools and methods to make their vision a reality.
We developed the world's first series of specialized molds for hybrid insulators, protected by core invention patents. This involved: Theoretical Breakthrough: Implementing a novel "Solid-Solid/Solid-Brittle" ternary second-order multi-modal interface coupling design theory. Precision Engineering: Overcoming extreme dimensional tolerance challenges to ensure structural consistency and control previously thought impossible.
Recognizing that off-the-shelf machines were insufficient, we designed and built China's (and the world's) first large-scale, specialized injection molding machines (e.g., WLT-SM360-II series), tailored specifically for the unique flow and curing characteristics of the insulation materials.
We pioneered a revolutionary short-flow, solid-state composite injection process. This new method drastically reduced the molding cycle by 50-60% and enabled complete, uniform material encapsulation.
Solves issues of large dimensional deviations, structural instability, and high brittleness found in traditional manufacturing. Overcomes limitations in mold technology, specialized equipment, and solid-state material processing.
We have engineered and deployed the world’s first dedicated, large-scale forming machine specifically for the new generation of hybrid insulators. This groundbreaking achievement is supported by a complete, automated production ecosystem, including:
1 fully automated production line for large hybrid insulators
1 automated flow production line for small-to-medium hybrid insulators
This integrated manufacturing infrastructure—featuring our proprietary New Generation Hybrid Insulator Forming Machine—transforms advanced theoretical innovation into reliable, high-volume production. It marks a decisive leap from laboratory breakthrough to industrial leadership, solidifying our capacity to supply the future of global UHV infrastructure.
The collaboration between Livepoint vision and our mold manufacturing expertise yielded historic results:
Unprecedented Product Quality: The new Hybrid Insulators outperform all existing solutions, with a tear strength of 15.81 kN/m (vs. 7 kN/m for composites) and superior tracking and erosion resistance (TMA 4.5 vs. TMA 2.5).
Manufacturing Revolution: Achieved a consistent, mass-production yield rate of over 95%, shattering the previous sub-10% industry ceiling.
Unmatched Longevity: Product life expectancy exceeds 70 years with a 50-year maintenance-free service guarantee, drastically reducing the lifecycle cost for grid operators.
A Chinese Solution: Successfully established a “Third Technical Route,” distinct from Japanese and European/American technologies, securing China’s independent intellectual property and leadership in UHV technology.
1. Japanese Insulator Technology (Glass Insulator)
Advantages:
Service life of up to 50 years.
Disadvantages:
Poor pollution flashover performance.
High operational and maintenance costs.
2. American Insulator Technology (Composite Insulator)
Advantages:
Excellent pollution flashover performance.
Disadvantages:
High material costs.
Poor mechanical and anti-aging performance.
Service life of only about 10 years.
3. China’s Newly Developed Insulator (Independent Intellectual Property)
Advantages:
Excellent mechanical and anti-aging performance.
Outstanding pollution flashover resistance.
Service life of up to 70 years, with 50 years of maintenance-free operation.
Cost-effective: unit price as low as 300–400 RMB per insulator.
“For years, the solution was a blueprint without a builder. Livepoint provided the critical engineering genius to construct it. Their ability to translate our complex theoretical models into patented, high-precision molds and a reliable production process was the decisive breakthrough. They were the key missing link that turned our national research project into a global industrial achievement.”
— Project Lead, University Consortium
Our core advantage is the proprietary integration of specialized molding equipment, innovative mold design, and standardized processes—the only solution enabling mass production of next-generation hybrid insulators globally.
To propose a “Chinese Solution,” forging a “Third Technological Path” distinct from Japanese, American, and European technologies.
To break through industry bottlenecks by achieving fundamental innovation in mold, equipment, and process technologies.
To develop original technological achievements protected by China’s independent intellectual property rights.
To support our province in achieving a leapfrog development from the “Capital of China’s Electric Porcelain” to the “Capital of China’s Electric Porcelain Technology.”
To become a global leader in UHV technology, contributing to UHV development initiatives in China and worldwide.
Modularization of Forming Molds: Break existing conventions and achieve theoretical innovation.
Specialization of Forming Equipment: Develop proprietary machinery through original innovation.
Industrialization of Technological Achievements: Innovate new processes and methodologies.
Innovative design theory for overmolding molds.
Research and development of specialized core overmolding equipment.
Standardization and industrialization of molding processes.
We are not just a supplier; we are the sole global partner capable of mass-producing the next-generation UHV hybrid insulator, a technology that redefines industry standards.
While competitors rely on outdated Japanese glass or Western composite insulator technologies, we have pioneered and patented the "Third Technological Path." Our solution delivers a superior combination of a 70-year lifespan, 50-year maintenance-free operation, and excellent pollution flashover performance at a fraction of the lifecycle cost.
The industry has struggled for a decade with low yield rates (<10%) and insurmountable problems in molding, materials, and specialized equipment. We broke this bottleneck by developing: The world's first dedicated large-scale forming machine for hybrid insulators. Proprietary mold design theories to control precision and eliminate defects. Fully automated production lines that ensure quality and scalability.
Our vertically integrated control over mold, equipment, and process means we deliver unprecedented batch-to-batch consistency, dimensional accuracy, and total reliability. You gain a partner who guarantees a critical component, eliminating the risk of grid failure and securing your project timeline.
We provide the only industrially viable, high-performance insulator that enables the next generation of safe, reliable, and cost-effective UHV networks.
GLOBAL PRECISION PLASTIC MOLD MANUFACTURER
