The World’s First UHV Hybrid Insulator for a Leading University Consortium in China
Livepoint partnered with a top Chinese university consortium to transform a groundbreaking academic UHV insulation concept into the world’s first mass-producible hybrid insulator through proprietary mold design, dedicated equipment, and a solid-state injection molding process.
2025-08-14
Project Background
This project originated from a national-level academic research initiative led by a consortium of China’s leading universities, including Tsinghua University, Wuhan University, and Nanchang University.
The objective: Develop a next-generation Ultra-High Voltage (UHV) insulation technology capable of supporting China’s rapidly expanding UHV power transmission network.
Industry:
Ultra-High Voltage (UHV) Power Transmission
Product:
UHV Hybrid Insulator
Services Provided:
Injection molding, mold design & manufacturing, rapid prototyping
Technology:
Solid-state composite injection molding
Materials:
High-performance insulation composites
Production Type:
Automated mass production
The Challenges
For years, the university research teams achieved significant theoretical breakthroughs in hybrid insulator design. However, the project faced a critical bottleneck: the lack of a viable manufacturing solution. Existing mold technologies, equipment, and processes were unable to meet the extreme requirements for dimensional accuracy, material integrity, and large-scale production. As a result, the innovation remained confined to the laboratory stage, with yield rates below 10% and no clear path to industrialization.
Our Solutions
Livepoint identified that conventional mold technologies, standard equipment, and existing processes were fundamentally incapable of meeting the extreme manufacturing requirements of UHV hybrid insulators. To bridge the gap between academic research and industrial production, we developed a fully integrated solution spanning mold design, equipment, and molding processes.
Proprietary Mold Design
We developed the world’s first proprietary molds for UHV hybrid insulators, protected by invention patents. A novel solid–solid / solid–brittle interface design enabled precise dimensional control and consistent structural integrity across large components.
Dedicated Molding Equipment
Because off-the-shelf machines were insufficient, Livepoint designed and built the world’s first large-scale, purpose-built forming machines for hybrid insulators, ensuring stable, repeatable production under demanding material and process conditions.
Solid-State Injection Molding
We pioneered a solid-state composite injection molding process that reduced molding cycles by 50–60% while enabling uniform material encapsulation. This approach effectively addressed material brittleness and significantly improved production yield.
Project Result
The collaboration between Livepoint and the university consortium successfully transformed a long-standing academic concept into the world’s first industrially viable UHV hybrid insulator. Key results include:
Unprecedented Product Performance
- Tear strength: 15.81 kN/m (vs. 7 kN/m for traditional composites)
- Superior tracking and erosion resistance: TMA 4.5 (vs. TMA 2.5 for existing solutions)
High-Yield Mass Production
- Achieved a consistent production yield of over 95%, compared to the previous industry ceiling of less than 10%
- Fully automated production lines for both large and small-to-medium hybrid insulators
Long-Term Reliability
- Product life expectancy exceeds 70 years
- 50-year maintenance-free service guarantee, significantly reducing lifecycle costs for grid operators
Industrial Impact
- First large-scale, dedicated forming machine for hybrid insulators deployed
- Integrated manufacturing ecosystem enables reliable, high-volume production for global UHV infrastructure
Independent Technological Leadership
- Established a Third Technical Route distinct from Japanese and Western technologies
- Secured China’s independent intellectual property rights in UHV insulation
Comparison with Existing Insulator Technologies
Japanese Glass Insulator
American Composite Insulator
China’s New Hybrid Insulator
- Service life of up to 50 years.
- Poor pollution flashover performance
- High operational and maintenance costs
- Excellent pollution flashover performance..
- High material costs.
Poor mechanical and anti-aging performance.
- Service life of only about 10 years
- Excellent mechanical & anti-aging performance.
- Outstanding pollution flashover resistance
- Service life: up to 70 years, 50 years maintenance-free
- Cost-effective: 300–400 RMB per unit
Partner's Feedback
"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
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