FutureWire Manufacturing Facility
TS Conductor Corp
Recipient
Huntington Beach, CA
Recipient Location
36th
Senate District
72nd
Assembly District
$1,195,882
Amount Spent
Active
Project Status
Project Update
TS Conductor is working to modernize the world’s power grids to meet the challenges of the 21st century and deliver affordable, reliable, and clean electricity. The "Covered Smart Conductor" is a type of electrical power transmission line developed by TS Conductor, which is a smaller, lighter conductor with a protective covering, designed to carry high currents while minimizing line losses and improving overall efficiency compared to traditional conductors.
The purpose of the grant agreement is to expand TS Conductor's manufacturing capabilities at its FutureWire facility in Huntington Beach, California. The facility will produce advanced, high-efficiency conductors that can reduce electricity line loss by 40 percent, allowing more generated electricity to reach load centers while lowering the carbon intensity of grid electricity. The project aims to design and commission a new manufacturing line capable of producing up to 2,300 miles of covered smart conductors per year and reduce manufacturing costs by 50 percent.
In 2024, the project team made progress to upgrade the current manufacturing process to accommodate smaller cores, in addition to increasing throughput, improving product quality consistency, and reducing manufacturing costs. Additionally, a clean room environment to produce defect-free multiple small cores and improve the quality control system has been accomplished. For 2025, the project team plans to install a resin system for the conductor with the intent of improving product quality.
The Issue
The electrical grid is overly reliant on century-old conductor technology that has no self-monitoring capability, poor efficiency, and limited capacity to handle the growing demands placed on the grid, related to additional renewable generation and electric vehicle integration. The extreme weather from climate change is disrupting the power grid in ways never seen before, as experienced in the recent Texas winter storm and California wildfires. As a result of unplanned outages, governments are mandating power system hardening for greater reliability, resiliency, and smart grid integration.
Project Innovation
TS Conductor Corp has developed advanced conductors designed to improve the efficiency, affordability, safety, reliability, and resiliency of the electricity grid. By reducing line losses, ratepayers benefit from lower power generation and power delivery costs. The CSC is embedded with a smart sensing capability, that produces real-time data on the status of the electricity grid that is not currently available, enabling a more reliable and resilient electricity grid. Additionally equipped with coating technology, this offers the electricity grid up to 300% ampacity with structures in an existing right of way, reducing congestion and allowing for increased electric vehicle penetration and increased capacity for integrating renewable energy onto the grid. The insulation technology applied to the CSC also increases the safety of powerlines by reducing the ignition risk associated with a wide range of fault conditions.
Project Benefits
This grant agreement will lead to technological advancement and breakthroughs to overcome barriers to the achievement of the State of California’s statutory energy goals by improving the efficiency, affordability, safety, reliability, and resiliency of the electricity grid. TS Conductor will develop new manufacturing processes to drive down costs and increase the supply of advanced conductors to enable the grid of the future which has more capacity for electric vehicle and renewable energy integration. New pultrusion, optical fiber insertion, and aqueous coating processes will be developed which provide a wide range of ratepayer benefits in California.
Reliability
Reliability
TS Conductor is working to modernize the world’s power grids to meet the challenges of the 21st century and deliver affordable, reliable, and clean electricity.
Key Project Members
Jason Huang
CEO & Founder
TS Conductor
Vivek Kohli
Chief Technology Officer
TS Conductor
Massimo Masini
Vice President
TS Conductor
Subrecipients
Match Partners
TS Conductor Corp
Cap Architecture Inc
