Flyaford
Flyaford
Precision-molded composite insulators for power distribution, switchgear, and renewable energy grids
Global Leadership in High-Performance Electrical Insulation Engineering & ODM Supply Chain Excellence
Established in 2007, ZHEJIANG FLYAFORD ELECTRON CO., LTD. is situated in the Jinyi New District of Jinhua City, Zhejiang Province, China. Spanning a state-of-the-art construction area of 35,000 square meters, Flyaford has grown into a globally recognized technological leader specializing in the research, design, compression molding, and international export of low-to-medium voltage electrical insulators and custom busbar support assemblies.
Our core capabilities encompass an end-to-end ODM/OEM engineering pipeline. Equipped with over 60 high-precision molding machines and more than 20 specialized electrical and mechanical testing instruments, our factory maintains a robust daily production capacity exceeding 200,000 pieces per day with an industry-leading quality defect rate strictly under 100 PPM. Through continuous scientific innovation and strategic academic partnerships—including designated research collaboration with Tsinghua University—we engineer high-integrity solutions that protect critical power infrastructure worldwide.
Advanced Thermosetting Polymers, Hardware Insert Engineering, and Dielectric Optimization
Polyester-based thermosetting compound reinforced with short glass fibers (10%-20%). BMC provides exceptional dimensional stability, high mechanical shock absorption, and cost-efficient compression molding for standard low-voltage switchgear, SM, EL, and D-type standoff insulators.
Formulated for demanding medium-voltage applications, EMC delivers superior CTI (Comparative Tracking Index > 600V), ultra-low partial discharge (< 5pC at rated voltage), and enhanced moisture resistance required for heavy-duty battery energy storage systems (BESS).
Phenolic thermosetting resins offer extreme flame retardancy (UL 94 V-0 certified), high heat deflection temperature (> 250°C), and chemical inertness. Ideal for extreme industrial environments, railway traction converters, and high-ambient frequency cabinets.
| Material Parameter | BMC Compound Standard | EMC High-Voltage Grade | PF Phenolic Resin Grade | Test Standard / Method |
|---|---|---|---|---|
| Dielectric Strength | 18 - 22 kV/mm | 25 - 30 kV/mm | 16 - 20 kV/mm | IEC 60243-1 / ASTM D149 |
| Comparative Tracking Index (CTI) | CTI 600 (PLC 0) | CTI 600+ (Extreme tracking ref) | CTI 175 - 275 | IEC 60112 / UL 746A |
| Flame Retardancy Rating | UL 94 V-0 (Self-extinguishing) | UL 94 V-0 / 5VA | UL 94 V-0 | UL 94 Vertical Burning Test |
| Thermal Shock Endurance | -40°C to +140°C | -50°C to +180°C | -40°C to +200°C | High/Low Temp Chamber (100 cycles) |
| Tensile & Flexural Strength | > 70 MPa / > 140 MPa | > 110 MPa / > 190 MPa | > 65 MPa / > 120 MPa | ISO 527 / ASTM D790 |
| Hardware Thread Torque Capacity | Up to 120 N·m (M16 insert) | Up to 180 N·m (M16 insert) | Up to 100 N·m (M16 insert) | Microcomputer Torsion Test (0-500N.m) |
Automated Molding Equipment, Complete Traceability, and Scientific Reliability Testing
Our smart factory integrates real-time digital monitoring and automated closed-loop parameter control across all 60+ thermosetting compression molding machines. From raw material batching to final automated packaging, data analytics optimize curing times, mold temperature, and pressure curves to eliminate internal voiding and structural micro-cracks.
This end-to-end automation provides 100% full-process traceability for every lot exported worldwide, safeguarding global supply chains against unexpected downtime.
To guarantee ultimate product reliability, Flyaford has invested millions in a municipal-certified testing laboratory. Equipment includes:
Engineered for mission-critical electrical environments across energy, transportation, and industrial automation
MNS, SM, and SB series standoff insulators provide physical isolation and rigid copper busbar support in air-insulated switchgear (AIS) cabinets up to 36 kV, enduring dynamic electrodynamic short-circuit forces.
Custom BMC/EMC D-type and T-type insulators isolate high-amperage battery busbars, preventing thermal runaway arc propagation and complying with strict fire safety standards.
Compliant with IATF 16949 automotive standards, our ultra-compact insulators secure high-voltage junction boxes, motor drive inverters, and high-frequency 5G base station power modules.
Custom Mold Engineering, Rapid Prototyping, and End-to-End Lifecycle Support
Our senior electrical engineering team reviews customer technical drawings, dielectric requirements, mechanical load forces, and environment conditions to optimize mold design.
In-house mold building allows rapid tooling turnaround. We supply initial molded samples with complete CTI, flammability, tensile, and dimensional inspection reports for customer verification.
Utilizing high-capacity compression presses, mass production maintains a defect rate under 100 PPM with 100% full visual and electrical withstand voltage verification prior to dispatch.
Custom packaging protects insulators during ocean freight. We provide full after-sales technical service, guaranteeing 2-hour response SLAs and 7*24 online support.
Expert Engineering Solutions for Switchgear Designers, OEM Procurement Managers, and Electrical Engineers
BMC (Bulk Molding Compound) consists of short glass fibers mixed with polyester resin, offering excellent balance of price and mechanical rigidity for low-to-medium voltage standoff insulators. EMC (Epoxy Molding Compound) uses high-grade epoxy matrix providing higher CTI values (>600V), superior moisture resistance, and minimal partial discharge for high-voltage energy storage systems. SMC (Sheet Molding Compound) contains longer glass fiber strands providing higher structural flexural strength for large structural insulation panels.
Our hardware inserts (brass, steel, or copper) are manufactured with deep diamond-pattern knurling and anti-pullout shoulders. During compression molding, thermosetting compound flows completely into the insert grooves. Every production lot undergoes microcomputer torque testing (0-500 N·m) to verify that thread torque limits far exceed standard IEC/NEMA busbar installation specifications.
Flyaford maintains certification under IATF 16949 (International Automotive Quality), ISO 9001 (Quality Management), ISO 14001 (Environmental System), UL 94 V-0 flammability certification, CE EU safety certification, and full compliance test certificates for ROHS 2.0 and REACH regulations.
Yes. We specialize in custom ODM/OEM production. Our engineering team designs custom molds according to customer working environment, creepage distance requirements, system operating voltage, and physical mounting constraints. 3D step files and CAD drawings are verified prior to rapid prototype mold making.
Flyaford produces over 200,000 insulator parts per day across 60+ automatic compression molding machines. Standard catalog models (SM, EL, MNS, SB series) are available from stock or delivered within 7-14 days. Custom ODM tooling and mass production delivery timelines typically range between 20 to 30 days.
Explore our complete catalog of low-medium voltage standoff insulators for energy storage and switchboards
