DIY High Voltage Insulator

I conducted several tests in order to test dielectric strength and find/create best high voltage insulator material. The goal was to use cheap and readily available materials without buying specialized expensive materials for high voltage insulation. This will be very useful for insulating flyback transformers, tesla coils, etc. The results were surprising.

Materials tested:

1. Regular Epoxy (Coating / Casting)
2. Aluminum Oxide, Alumina, Al2O3
3. Mica powder
4. Regular mineral oil

Mix equal parts of Epoxy-A to Epoxy-B. Add additive (whatever) you are using. Mix it thoroughly for 3-5mins.

Pour the mixture into mould. I added screws on side of mould so that they are completely covered in epoxy. Distance between screws and applied voltage will determine strength of material. This is a relative test. Degass for at least 30mins (will depend on epoxy you are using). Cure epoxy for at least 48hours.

I used fly back transformer to test dielectric strength. I increased voltage until the material breaks down. Distance between electrodes and voltage at which material breaks down will allow us to compare materials tested.