Design teams are often challenged to push the limits of performance, which naturally leads to exploring the boundaries of what’s safe, reliable, and technically feasible. One curious individual decided to investigate what happens when a motor is pushed beyond its voltage limits—or when insulation isn’t properly rated.
To illustrate the risks, they asked Engineering for a practical example. The result? A high-voltage demonstration, an under-insulated setup, and a lesson that left a lasting impression—along with a temporary lab ban.
The electrical arc captured in the video was part of a controlled experiment. Nearly 3,000 volts were applied across a setup intentionally designed with insufficient insulation to show just how critical proper electrical insulation really is. The flash lasted less than 1/25th of a second—but the message was clear.
When insulation fails, the consequences are immediate and serious:
These aren’t hypothetical risks. They’re real-world dangers that can harm people, destroy components, and compromise entire systems.
While the large arc made for a dramatic visual (and some impressive lens flaring), smaller arcs can be even more insidious. Instead of causing immediate failure, they may slowly degrade components, allowing unsafe systems to continue operating unnoticed.
Proper insulation isn’t something to be bolted on at the end of a project. It must be engineered into the design from the beginning. That means accounting for:
Getting insulation right requires deep application knowledge, careful materials selection, and a holistic understanding of how every part of a system works together.
A knowledgeable supplier or design partner doesn’t just follow a checklist. They anticipate potential issues, select appropriate components, and safeguard the system before it’s ever powered on. Whether dealing with high voltages, fast-switching electronics, or compact embedded systems, the right insulation—and the right expertise—can prevent the kind of trouble that led to this unforgettable lab moment.
What’s seen in the image is an engineered failure. What professionals strive for is engineered success—built on robust design, informed decisions, and components that perform safely and reliably.