Custom Thermoset Molded Parts
Our team of experts is ready to help you create custom thermoset molded components that meet your specifications and enhance your products’ functionality and safety through our custom molding services.
Our molding capabilities were made possible by our acquisition of a minority stake in Powercam Electricals Pvt. Ltd. in March 2024. Powercam, operating under the Powermat brand, brings significant expertise in material compounding and the manufacture of molded electrical components. As part of The Gund Company’s long-term strategy to enhance our molded product capabilities, we found that Powercam’s facilities in India complement our own. This partnership continues to foster collaborative development and innovation.
To understand more about Powermat’s capabilities, please visit powermatindia.com.
- Full catalogue parts to match your application requirements
- UL listed Materials and parts
- Testing assistance on UL, IEC and others in our lab
- Tailored Solution: adjusting exactly to what is required from the electrical system
- Quality and Reliability: 99% quality rating
- Lowest TCO ( total cost of ownership) when working with TGC
BMC/DMC STANDOFF INSULATORS
Bulk Molding Compound (BMC)/Dough Molding Compound (DMC) are polymeric composite materials made of a mixture of unsaturated polymer resin, processing additives, cross-linked catalysts, shrink control polyester, mold release agent, fire retardant agent, color pigments, inorganic fillers, and glass chops. Its strong mechanical and electrical insulating properties make it an ideal material for supporting bus bars or other live electrical components.
The material is compression molded into a variety of shapes which commonly include metallic inserts such as threaded inserts for mechanical connections and improved mechanical strengths.
- Made from bulk molding compound, which is made from thermosetting resins, glass fibers, fillers, and additives
- Strong mechanical and electrical insulating properties
- UL-94 flammability rate V-0
- Made from UL-listed BMC material – E249670
- Our catalogue parts are UL-recognized panelboard and switchboard accessories that comply with the brace and support requirements of UL 891 Annex G.: UL File E354884
- The standoff insulator inserts can be manufactured in aluminum, steel, or brass
- You can match your current standoff with ours on the line card
- Stock available to fulfill your requirements
Select the standoff insulator to view it’s technical drawing:
GINS 1461 2C Series
GINS 1461 Series
GINS 1603 Series
GINS 1872 Series
GINS 2015 Series
GINS 2017 Series
GINS 2165 Series
GINS 3061 Series
GINS 4610 Series
GINS 4640 Series
ISO-TP POLYAMIDE STANDOFF INSULATORS
ISO-TP Standoff Insulators are a glass fiber-reinforced polyamide 66 resin. It’s a more robust material, both
mechanically and electrically, compared to sheet molding and dough molding compounds. The flammability index
of this material is V0 as per UL 94. Polyamide 66 has high abrasive resistance, good insulating properties, and
resistance to organic chemicals like alkalies.
- Polyamide reinforced with glass fiber
- Halogen free
- UL-94 flammability rate V-0
- High mechanical and electrical properties
- Our catalogue parts are UL-recognized panelboard and switchboard accessories that comply with the brace and support requirements of UL 891 Annex G
- Available on steel zinc plated inserts, brass or aluminum
- UL Listed: UL 891 Annex G UL FILE E314972
- Compliance with IEC 61439
- Recyclability
Select the image to view the technical drawing:
EPOXY STANDOFF INSULATORS
Cycloaliphatic Epoxy is a low viscosity, low molecular weight, epoxy resin designed for high voltage outdoor electrical
applications. The epoxy resin system delivers crack-free components with excellent mechanical and electrical properties with high uniformity. It also provides good thermal shock resistance and is suitable for use in outdoor applications.
When the hardener, accelerator, and filler are mixed with epoxy resin and cast under a vacuum, crack-free components with
excellent mechanical and electrical properties can be achieved with high uniformity. This system provides good thermal shock resistance and is suitable for use in outdoor applications.
BUS SUPPORTS AND BMC/SMC CUSTOM
Bus bar standoff insulation is made of polymeric composite material that has received UL recognition. The production process is regulated by a manufacturing environment compliant with ISO 9001:2015. Each lot is mechanically and electrically tested to ensure performance and dependability for the most demanding electrical applications.
The Gund Company offers testing capabilities for our customers’ new product designs for all electrical and mechanical properties. We maintain stock in the US, with orders shipping within 24 hours.
- Testing: We can test mechanical end electrical properties using UL, IEC, and others
- Material Selection: We produce our own type of BMC (Bulk Molding Compound) and SMC (Sheet Molding Compound}. Both materials are UL-listed, and we can help you list and update your UL file
- Fast Turnaround Time: We can take a part from drawing to production in just 4-6 weeks, ensuring the functionality of your components
What to Expect When Working With Us
Our team manages the full process from initial design review through production and delivery, with in-house material compounding, molding, testing, and stock management under one operation. This gives customers a single point of contact from design assistance through ongoing supply.
Testing is available for all electrical and mechanical properties using UL, IEC, and other standards at our in-house facility. For customers who need a new UL listing or need to update an existing file, we can assist with that process as part of the custom molding program.
Our North American inventory is maintained in the US, with standard catalog parts shipping within 24 hours. Custom parts move from drawing to production in four to six weeks. Our production quality rating across all molded components is 99%.
For customers interested in understanding the capabilities that support our molding program through our Powermat partnership, additional information is available at powermatindia.com.
Frequently Asked Questions
BMC (Bulk Molding Compound) and SMC (Sheet Molding Compound) are both thermoset composites with similar electrical and mechanical performance, but they are suited to different part geometries. BMC is used for smaller, more complex three-dimensional shapes such as standoff insulators and bus supports. SMC is better suited to larger, flatter panel-format parts where consistent wall thickness across a larger surface area is important. For standoff insulators, BMC is the standard material.
Our BMC/DMC standoff insulators are manufactured from UL-listed BMC material (UL File E249670) and the catalog parts are UL-recognized under UL 891 Annex G (UL File E354884). Our ISO-TP polyamide standoff insulators are UL-listed under UL 891 Annex G (UL File E314972) and are compliant with IEC 61439. Epoxy standoff insulators are designed for high-voltage outdoor use. Contact us for specific compliance documentation for your design.
Yes. Our line card covers a wide range of standard standoff insulator series across BMC/DMC and ISO-TP polyamide materials. If you share your current part number or dimensional drawing, our team can identify the matching series from our catalog. We can also advise on how to use our catalog standoffs in your design without the need for additional UL testing in many cases.
For custom thermoset molded components using BMC or SMC, our typical lead time from confirmed drawing to production is four to six weeks. This includes design review, tooling, material compounding, and first article inspection. Contact us early in your design cycle if schedule is a constraint, as our engineering team can review your design for manufacturability before tooling begins.
Our BMC/DMC standoff insulators are available with inserts in aluminum, steel, and brass. Our ISO-TP polyamide standoff insulators are available with steel zinc-plated, brass, and aluminum inserts. The insert material affects both the mechanical connection strength and the corrosion resistance of the assembly. Our team can recommend the appropriate insert material based on your installation environment and mechanical load requirements.
Yes. Our bus bar support components are manufactured from UL-listed BMC material and are UL-recognized as panelboard and switchboard accessories complying with the brace and support requirements of UL 891 Annex G. Our manufacturing environment is certified to ISO 9001:2015 and each production lot is tested for mechanical and electrical performance before shipment.
Yes. Because we produce our own UL-listed BMC and SMC compounds, we can assist customers who need to list a new custom component or update an existing UL file. This is particularly relevant for electrical OEMs developing new panelboard or switchgear designs that require UL-recognized components. Contact our team at the beginning of your design process to discuss the listing path alongside the design and tooling process.
Minimum order quantities vary by part complexity, tooling requirements, and compound type. Contact our team with your part drawing, material requirement, and estimated annual volume, and we will provide a quote that includes tooling amortization options and per-part pricing at your target quantities.