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Solution

Custom Formulation and Tooling

Changing a wall thickness a shrink ratio a colour or a molded shape when the catalogue does not fit

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Custom Formulation and Tooling

The Problem

Why This Is Harder Than It Looks

A catalogue is a compromise. It covers the sizes that most customers need most of the time. When your bar section, your joint geometry or your operating environment falls outside it, the question is whether your supplier can actually change something or only tell you what is in stock.

Process

From Requirement to Delivered Product

Design material selection prototyping production quality control packing logistics and after sales

  1. 01

    Design

    Send a drawing a sample or a photograph with a scale. For a formulation change tell us the operating condition that the standard grade does not survive.

  2. 02

    Material Selection

    Wall thickness shrink ratio colour chemical resistance and temperature range are all formulation variables we control because we compound our own material.

  3. 03

    Prototyping

    A first article is produced and measured against the drawing. For molded parts a fit check on your actual assembly comes before production tooling is committed.

  4. 04

    Production

    Extrusion irradiation expansion and molding in our own plant which is why a change does not need a third party to agree to it.

  5. 05

    Quality Control

    The first article is the reference. Every production lot is checked against it and against the standard property tests in our own laboratory.

  6. 06

    Packing

    Custom parts are packed and labelled to your part number scheme.

  7. 07

    Logistics

    First article shipped for approval then production against your schedule.

  8. 08

    After Sales

    Tooling stays available for repeat orders so the second order is faster and cheaper than the first.

Products

Products Used in This Solution

S1-B Busbar Lap Joint Insulation Cover 1 kV to 36 kV
S1-B

S1-B Lap Joint Cover

Molded clip open covers that insulate bolted busbar joints and still allow inspection without damaging the connection

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Y1 Heat Shrink Breakout Boots for Multi Core Cable
Y1

Y1 Breakout Boots

Molded two three four and five leg boots with adhesive on the big end and every leg for 1 kV to 36 kV cable

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S1-A Wrap Around Overhead Line Cover 380 V to 110 kV
S1-A

S1-A Overhead Line Cover

A wrap around insulating cover with a built in creepage device that clips onto a live route conductor without disconnection

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C107 Plastic and Elastomeric Insulation Double Layer Heat Shrink Tube
C107

C107 Insulation Tube

Ultra heavy wall insulation for joints where the cable screen is restored separately from 6 kV to 36 kV

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S3(h) Heavy Wall Flame Retardant Heat Shrink Tube
S3(h)

S3(h) Heavy Wall FR

The toughest tube in the S3 family combining flame retardant marine formulation with a thickened heavy wall

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T1 Compound Insulation Heat Shrink Tape
T1

T1 Heat Shrink Tape

Adhesive lined heat shrink tape that seals and insulates irregular shapes where no tube or sleeve will fit

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Outcomes

What You Get

  • A part that fits your geometry rather than one you have to work around
  • Formulation changes without going through a compound supplier
  • A first article to approve before production tooling is committed
  • Tooling retained so repeat orders ship faster
  • 24 years of formulation experience behind the change you are asking for

FAQ

Custom Formulation and Tooling Frequently Asked Questions

What can actually be customised
Wall thickness shrink ratio colour chemical resistance temperature range printed marking kit contents and molded geometry. Tell us the requirement and we will tell you honestly whether it is achievable.
How much does molded tooling cost
It depends entirely on the part size and complexity. Send a dimensioned drawing and we will quote tooling and unit price together so you can see the real cost per part at your volume.
How long does a first article take
Typically 20 to 30 working days for a molded part. A formulation or dimension change on an extruded product is faster.
Do we own the tooling
Tooling ownership is agreed in the quotation. Say what you need and we will structure it that way.
Can you match a competitor part we currently buy
Send a physical sample and the dimensions you need held. We reverse engineer to function not to appearance and we will tell you where we differ.
Is there a minimum volume for a custom formulation
Yes because a compound batch has a minimum size. Tell us the annual volume and we will tell you whether a custom grade or a modified standard grade is the sensible route.

Still need an answer ask our engineers on WhatsApp

Other Solutions

Explore the Rest

Medium Voltage Cable Jointing

Rebuilding insulation screen and sealing across a jointed conductor from 6 kV to 36 kV

Cable Termination Indoor and Outdoor

Field grading anti tracking insulation and creepage from 0.6/1 kV to 26/35 kV

Switchgear and Busbar Insulation

Raising internal clearance inside compact switchgear and covering the joints a tube cannot reach

Emergency Cable Repair

Restoring a damaged jacket in place without cutting the cable or disturbing the terminations

OEM and Private Label Kits

Kits packed to your bill of materials with your brand on the carton the instruction sheet and every bag

Start a Conversation About Custom Formulation and Tooling

Send a drawing a cable schedule or a photograph. Our engineers answer directly on WhatsApp with no sales gatekeeper.

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