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CNC Machined PEEK Insulator Block for High-Voltage Electrical Systems
PEEK (polyetheretherketone) is one of the few engineering plastics that can serve as both a structural component and an electrical insulator at 150°C+ operating temperatures. Its dielectric strength is around 20 kV/mm, meaning a 5mm wall thickness can hold back 100,000 volts—but only if the wall is dimensionally consistent and free of cracks, voids, or stress concentrations from poor machining.
We machine PEEK insulator blocks on CNC milling centers with specific process parameters optimized for this material. The spindle speed is higher (8,000-12,000 RPM), the feed rate is lower to prevent melting, and we use compressed air instead of flood coolant. Critical features include bore holes, mounting hole positions, and creepage distances between conductive paths, all maintained to ensure IEC 60664 compliance.
Key Features
Victrex PEEK 450G or Equivalent: Grade-specific PEEK with full material traceability and material test reports
Creepage Distance Control: Slots and barriers machined to ±0.05mm positional accuracy with Ra 1.6 or better surface finish
Thermal Stability: Maintains mechanical and dielectric properties up to 250°C
Stress-Free Machining: Low depth of cut, high spindle speed, air blast cooling with post-machining annealing
High Dielectric Strength: 20 kV/mm dielectric strength with CTI 175V minimum for unfilled PEEK
Unfilled PEEK or carbon-filled PEEK for my insulator?
Unfilled PEEK (450G) for 95% of insulator applications. It has the highest dielectric strength and best tracking resistance. Carbon fiber filled PEEK (450CA30) is mechanically stronger but reduces dielectric strength by about 30%. Use CF-PEEK only when the insulator serves as a structural load-bearing component.
Can PEEK replace ceramic insulators?
Yes, in many medium-voltage applications. PEEK has better impact resistance, thermal shock resistance, and can be machined into complex shapes. The limitation is surface tracking—for polluted environments, you may need longer creepage distances in PEEK than in ceramic.
Why anneal PEEK after machining?
Machining introduces residual stress that can cause warping at elevated operating temperatures. Annealing relieves these stresses in a controlled manner, ensuring dimensional stability and maintaining proper creepage distances during service.
What's the maximum voltage rating for a PEEK insulator block?
The voltage rating depends on design factors including creepage distances, wall thickness, and pollution degree. Medium-voltage switchgear up to 36kV class commonly uses PEEK insulators. For high-voltage applications (>36kV), ceramic or composite insulators are typically preferred.
Can you machine PEEK insulators with metal inserts?
Yes. We can install threaded brass or stainless steel inserts (heat-set or ultrasonically installed) with controlled processes to avoid cracking the PEEK. Insert pull-out strength is tested on a sample basis.
What's the lead time for 50 insulator blocks?
7-10 days for unfilled PEEK (450G) with no inserts. Add 3-5 days for inserts, 5-7 days for carbon-filled PEEK. Material availability may affect lead times for specialty grades.
