From CAD to Kilovolts: How Custom Dielectric Components Are Engineered at PBI
In high-voltage electrical systems, success depends on components you can’t afford to get wrong. Bushings, insulators, arc chutes, and line sensors must perform flawlessly under mechanical, thermal, and dielectric stress—often in harsh, unpredictable environments. That’s why off-the-shelf parts often fall short, especially when retrofitting legacy systems or designing next-generation switchgear.
At Piedmont Bushing & Insulators (PBI), we offer custom-engineered dielectric components that are purpose-built for demanding utility and OEM applications. From the first CAD drawing to final high-voltage testing, we manage every stage of design and manufacturing in-house—delivering parts that meet exact specifications and exceed expectations.
This post offers a behind-the-scenes look at how PBI turns engineering challenges into high-performance solutions.
Why Custom Engineering Matters
Utilities and equipment manufacturers face increasingly complex requirements:
Aging infrastructure that requires retrofit compatibility
Compact designs with tight clearances
Ever-higher dielectric and mechanical performance standards
Supply chain disruptions that make fast, reliable sourcing critical
Standard components often fail to address these demands. Custom dielectric parts—designed for your application—offer a smarter, more efficient alternative.
Step 1: Engineering Design & CAD Modeling
It all starts with a conversation. Our engineering team works directly with your designers or maintenance team to understand:
Voltage and current ratings
Mechanical load requirements
Environmental conditions (e.g., temperature, moisture, contamination)
Mounting configurations or retrofit constraints
Regulatory or OEM compatibility standards
From there, we develop detailed CAD models using SolidWorks and other precision design tools. Our in-house design team is well-versed in ANSI, IEEE, and utility-specific standards, ensuring your components are engineered with reliability and field compatibility in mind.
Common design considerations include:
Maximizing creepage and clearance distances
Balancing dielectric strength with mechanical performance
Optimizing geometry for manufacturability and fit
Step 2: Material Selection and Prototyping
PBI’s Polykeram composite is at the heart of many of our custom products. It offers:
Higher dielectric strength than porcelain
Superior thermal shock resistance
Greater mechanical toughness
Better moldability for custom geometries
Depending on your requirements, we may also recommend other dielectric materials or hybrid assemblies.
Once design is finalized, we create prototypes using in-house tooling and molding. This accelerates development and ensures tight control over form, fit, and function. For utilities replacing aging or discontinued parts, we can reverse-engineer components using physical samples or legacy drawings—even when OEM support is no longer available.
Step 3: In-House Manufacturing & Quality Assurance
Unlike many suppliers who outsource production, PBI performs all critical manufacturing operations in our U.S.-based facility. This allows us to:
Ensure consistent quality and traceability
Avoid offshore delays and tariffs
Scale from short-run custom builds to full production volumes
Deliver rapid lead times for urgent or seasonal demands
Every part we produce undergoes rigorous quality control, including:
Dimensional verification
High-voltage dielectric testing
Thermal cycling and stress testing (as needed)
Lot tracking and documentation for utility compliance
We also support just-in-time manufacturing for OEMs looking to streamline inventory while maintaining component availability.
Real-World Applications
PBI’s custom dielectric solutions are deployed across North America in:
Refurbished breakers where new bushings or arc chutes must match discontinued OEM specs
New switchgear designs requiring compact, high-performance insulators
Arc chute assemblies where thermal and dielectric performance are critical under fault conditions
Line sensors and monitoring systems that rely on precise dielectric isolation and rugged housings
Whether you’re upgrading legacy assets or designing new equipment, PBI’s custom parts help ensure safe, stable operation across voltages and applications.
Industry Trends: Why Custom Matters Now
The demand for custom-engineered components is accelerating—driven by shifts in infrastructure, technology, and supply chain expectations:
Grid Modernization & Retrofit Compatibility
Utilities must extend the life of assets while upgrading systems. Custom parts enable drop-in replacements that meet modern specs without redesigning entire systems.
Domestic Manufacturing & Tariff Avoidance
With global delays and rising import costs, OEMs and utilities are turning to U.S.-based partners like PBI for dependable lead times and tariff-free sourcing.
Compact, Modular Designs
Next-generation switchgear and sensors are smaller and more integrated, requiring dielectric components with tight tolerances and nonstandard geometries.
Accelerated Development Timelines
Custom solutions—especially those supported by rapid prototyping and in-house molding—allow engineers to move from concept to production faster than ever.
Why Engineers Choose PBI
Deep technical expertise in high-voltage applications
Collaborative engineering support from concept through production
In-house tooling, molding, and testing
Polykeram composite material for superior performance
Reliable U.S.-based supply with fast, flexible turnaround
Whether you’re specifying a bushing, designing a new insulator, or solving a long-standing arc chute issue, we’ll work with you to develop a solution that fits—both physically and operationally.
Ready to Go From CAD to Kilovolts?
Let’s turn your challenge into a custom dielectric solution built to perform under pressure.