To reduce the SF6 usage as well as the material and space costs in gas insulated switchgear (GIS), compact GIS devices with downsized solid spacers is urgently required. In this paper, a tool chain for the design and prototyping of compact GIS basin spacer is proposed. Firstly, the concept of geometrical optimization and functionally graded materials is combined to design compact GIS spacers with significantly improved surface electric field distribution. Then, hollow-structure 3D printing is integrated with vacuum infilling to build downsized (10:1) prototyping 550kV spacer with both optimized structure and permittivity gradients. Experimental results indicate that the surface flashover voltage can maintain the same level in the 10:1 prototyping insulator under 0.1 and 0.2MPa SF6 gas, even with 10% reduction in outer tank’s diameter. Therefore, the effectiveness of proposed tool chain is verified for the development of compact GIS spacer.

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