In the fields of high-voltage inverters, medical imaging equipment (X-Ray/CT), precision high-voltage instruments, and high-energy physics research, METALLUX AG's HVR Series (HVR 967 / 968 / 969) from Germany has long been regarded as the industry benchmark for high-voltage thick film resistors. Its products are renowned for high precision, low temperature coefficient of resistance (TCR) and high stability, defining high-voltage resistor standards across Europe and globally.

However, in the current global manufacturing landscape, over-reliance on a single European supply chain is becoming a systemic risk. METALLUX products face pain points such as long lead times (typically over 20 weeks), high prices and slow response to non-standard customization, severely restricting the R&D and delivery pace of downstream equipment manufacturers.

HVC Company adheres to the manufacturing philosophy of "specialization in one's field," leveraging its deep expertise in high-voltage insulation materials to launch the HVR Series (covering HVRGXP Flat Style and HVR-Tube Cylindrical Style), specifically designed to fill the gap in high-end alternatives. This series is based on a 96% high-purity alumina substrate and a ruthenium oxide (RuO₂) slurry system. It not only achieves Pin-to-Pin compatibility with METALLUX in physical dimensions but also surpasses it in high-voltage linearity (VCR), pulse withstand capability and cost-performance ratio through its unique non-inductive serpentine printing technology and laser trimming process. It is currently the best engineering choice for replacing METALLUX.

1. Industry Background: Breaking the "Aloof" Barrier of German Supply Chains

METALLUX, as a long-established European manufacturer of high-voltage components, boasts exquisitely designed products. However, when facing the rapidly changing Asian and global markets, its supply chain rigidity issues are becoming increasingly prominent.

1.1 The "Grey Rhino" Crisis of the Supply Chain

For equipment manufacturers in China and globally, procuring METALLUX products presents an "unbearable burden":

• Lead Time Bottleneck: Restricted by the production capacity flexibility of European factories and complex logistics chains, METALLUX standard products have lead times of 16-24 weeks. In case of raw material fluctuations or production line maintenance, lead times can even be delayed to over half a year, which is fatal for modern manufacturing pursuing "zero inventory" and rapid iteration.
• Customization Threshold: High-voltage resistors are used in a myriad of application scenarios, often requiring non-standard resistance values (e.g., 123MΩ for specific voltage division ratios) or special pin configurations. The original manufacturer is often unresponsive to such demands, and the Minimum Order Quantity (MOQ) is extremely high, making it difficult to obtain samples during the R&D phase.
• Cost Pressure: Brand premium coupled with exchange rate fluctuations keeps METALLUX's procurement costs high, squeezing the profit margins of equipment manufacturers.

1.2 HVC's "Dimensionality Reduction" Strategy

HVC is not merely a "low-cost alternative" but a "technological upgrade." We leverage our technical reserves in manufacturing 100kV ultra-high voltage capacitors to redefine the manufacturing standards for high-voltage resistors.

• Voltage Dominance: HVC offers withstand voltage capabilities up to 50kV (in air) and even 100kV (in oil), fully covering and surpassing METALLUX's application range.
• Supply Chain Resilience: As a source factory, we compress standard lead times to 4-6 weeks, with urgent orders requiring only 2 weeks, and no high MOQ threshold, truly achieving "domestic speed."

2. In-depth Technical Analysis: How HVC Achieves "Outperforming the Master"

The reason why the HVC HVR series can be called an "expert-level" alternative stems from our deep exploration in material science and microstructure design. The following technical details are strictly based on the actual process of HVC Flat Style High Voltage Resistor and are deeply benchmarked against METALLUX.

2.1 Substrate Revolution: 96% Alumina (Al₂O₃) vs. Ordinary Ceramics

The heat dissipation capability and long-term stability of a resistor largely depend on the substrate material.

• METALLUX Standard: Some products use industrial-grade 85% or 90% alumina ceramic substrates.
• HVC Expert-Level Process: The HVRGXP series comes standard with 96% high-purity alumina (Al₂O₃) substrates.
• Thermal Advantage: The thermal conductivity of 96% alumina (approx. 24-28 W/m·K) is significantly higher than that of ordinary 85% alumina. Under high-voltage loads, this means lower "hot spot" temperatures on the resistor surface and more uniform thermal stress distribution, thereby greatly reducing the resistor's aging drift.
• Mechanical Advantage: High-purity substrates have better density and higher mechanical strength, making them less prone to breakage under vibration or thermal shock, especially suitable for automotive or industrial vibration environments.

2.2 Slurry Formulation: Precision Control of Ruthenium Oxide (RuO₂)

The core of thick film resistors lies in the conductive slurry.

• HVC Expert-Level Process: We use a high-grade ruthenium oxide slurry system, combined with a special glass phase binder. By precisely controlling the sintering temperature curve (850℃ high-temperature sintering), an atomic-level strong bond is formed between the film layer and the substrate.
• Low Voltage Coefficient (Low VCR): A key indicator for high-voltage resistors is the Voltage Coefficient of Resistance (VCR), which is the degree to which resistance changes as voltage increases. HVC controls VCR to an extremely low level (typically < 1-5 ppm/V) by optimizing the microscopic topological structure of conductive particles. This is crucial for high-voltage dividers, ensuring sampling linearity from 100V to 30kV.
• Ultra-Wide Resistance Range: Relying on our proprietary formula, HVC can achieve continuous resistance coverage from 100Ω to 10GΩ. Whether for low-resistance current limiting applications or extremely high-resistance insulation detection, a single component can achieve this, eliminating the need for multiple components in series.

2.3 Structural Design: Non-Inductive Serpentine Printing

In X-ray machine power supplies or pulse modulators, the parasitic inductance of resistors can lead to waveform distortion, overshoot, or even oscillation.

• HVC Expert-Level Process: The HVRGXP series abandons simple linear printing and adopts a unique computer-optimized serpentine printing path.
• Principle: By precisely calculating the direction of adjacent current paths, the magnetic fields are canceled out using the principle of mutual inductance, reducing parasitic inductance to the microhenry (µH) level.
• Value: Under high-frequency pulses, HVC resistors still exhibit pure resistive characteristics, with no overshoot or oscillation, perfectly protecting expensive switching devices such as downstream IGBTs or MOSFETs.

2.4 Protection Upgrade: Vacuum Epoxy Encapsulation (Conformal Coating)

• HVC Expert-Level Process: The HVR series uses high-density blue or black epoxy resin vacuum encapsulation.
• Insulation: Eliminates internal air bubbles and pinholes in the coating, passing rigorous Double 85 tests (85℃/85%RH), ensuring no surface flashover in high-humidity environments.
• Environmental Adaptability: Possesses excellent oil resistance and chemical corrosion resistance, making it ideal for use in oil-filled HV supplies or SF6 gas insulated switchgear, without reacting with the insulating medium.

3. Precise Benchmarking: METALLUX vs. HVC Model Comparison Table

To ensure Drop-in Replacement, HVC has meticulously compiled the following comparison table based on METALLUX specifications, covering both flat and cylindrical mainstream forms.

3.1 Flat Style Replacement: Benchmarking METALLUX HVR 967

METALLUX HVR 967 is the most commonly used flat high-voltage resistor, often found in compact high-voltage modules. HVC's HVRGXP series is fully compatible in terms of size, power, and pin spacing.

Complete online version please refer to: METALLUX HVR Series Replacement Solution

1. High Voltage Thick Film Flat Resistor (HVR 967 Flat Style) → HVC HVRGXP/HVRGFP Series

Dimension note: A(L)=length, B=width, C=pin spacing, d=pin diameter

Metallux Model	Power(W)	Working Voltage(kV)	A(L)(mm)	B(mm)	C(mm)	Thickness(mm)	d(mm)	HVC Replacement Model
HVR967.3.25	1	12	25.4	3.8	22.9	2.5	0.8	HVRGXP4.25
HVR967.3.38	1.5	15	38	3.8	35.7	2.5	0.8	HVRGXP4.38
HVR967.5.13	1	7.5	12.7	5	10.2	2.5	0.8	HVRGXP5.13
HVR967.7.51	2	30	51.9	7	48	2.5	0.8	HVRGXP7.52
HVR967.8.26	2	15	25.4	8	22.5	2.5	0.8	HVRGXP8.25
HVR967.13.38	3	30	38.5	13	36	2.5	0.8	HVRGXP13.39
HVR967.15.30	3	30	30	15	22.1	2.5	0.8	HVRGXP15.30
HVR967.15.51	4.5	45	50.8	15	48.3	2.5	0.8	HVRGXP15.51
HVR967.15.76	5.5	52	76.2	15.5	73.2	2.5	0.8	HVRGXP16.76
HVR967.25.90	10	67	88.9	25.4	85.6	2.5	0.8	HVRGXP25.89

3.2 Cylindrical Style Replacement: Benchmarking METALLUX HVR 968/969

For METALLUX's precision cylindrical HVR 968 and high-power cylindrical HVR 969, HVC offers the HVR-Tube Series of tubular thick film resistors.

2. High Voltage Thick Film Tubular Resistor (HVR 968) → HVC HVR-BSP Series

Dimension note: A=resistor body length, B=resistor outer diameter, d=pin diameter

Metallux Model	Power(W)	Working Voltage(kV)	A(mm)	B(mm)	d(mm)	HVC Replacement Model
HVR968.2	3.8	13.5	27	8	0.8	HVRBSP27
HVR968.3	5	18	37	8	0.8	HVRBSP37
HVR968.4	6	21	47	8	0.8	HVRBSP47
HVR968.5	7.5	27	52	8	0.8	HVRBSP52
HVR968.7	10	36	78	8	0.8	HVRBSP78
HVR968.10	12	54	102	8	0.8	HVRBSP102
HVR968.12	15	63	123	8	0.8	HVRBSP123
HVR968.15	17	81	153	8	0.8	HVRBSP153

3. High Power Tubular Resistor (HVR 969) → HVC HVR-PFS Series

Dimension note: L=resistor body length, B=flange spacing, ø=resistor outer diameter, D=mounting hole diameter, G=thread specification

Metallux Model	Power(W)	Working Voltage(kV)	L(mm)	B(mm)	ø(mm)	D(mm)	G	HVC Replacement Model
HVR969.11	11	32	81	14.5	13	10	M4	HVRPFS81
HVR969.23	23	72	156	14.5	13	10	M4	HVRPFS156
HVR969.54	54	72	160	31.1	30.5	18	M8	HVRPFS160
HVR969.71	71	96	209	31.1	30.5	18	M8	HVRPFS209
HVR969.105	105	148	309	31.1	30.5	18	M8	HVRPFS309

Note: HVRGXP suffix numbers (e.g., 5.10, 7.26) directly correspond to the millimeter-level dimensions of the substrate, ensuring mounting hole pitch is identical to METALLUX.

4. Why Choose HVC? Strategic Value Beyond "Replacement"

Choosing the HVC HVR series is not just about replacing a BOM part number; it is about introducing a more flexible, more high-voltage-savvy partner.

4.1 Customization Service "Dimensionality Reduction"

METALLUX, as a major manufacturer, is often unresponsive to non-standard requirements, often demanding extremely high MOQs (e.g., 1000pcs minimum).

• HVC Advantage: Relying on our laser trimming production line, HVC has turned "customization" into "standard service".
• Any Resistance Value: Whether it's a standard 10MΩ or a special 123.4MΩ, we can precisely trim the resistance, with MOQ as low as 50pcs.
• Any Tolerance: We offer a full range of tolerances: ±10% (K grade), ±5% (J grade), ±1% (F grade), and even ±0.5% (D grade).
• Flexible Leads: We provide tinned copper wire, screw caps, or special lead bending services (L-Bend, Z-Bend).

4.2 Excellent Pulse Withstand Capability

In high-voltage applications, pulse failure is a common issue. METALLUX products occasionally experience film thermal breakdown under high-energy pulses.

• HVC Advantage: By optimizing the film thickness and substrate thermal capacity, HVC products' pulse energy withstand capability has been improved by 30%. This means HVC resistors are less prone to open-circuit failure during X-ray arcing or grid surges, significantly improving the entire machine's MTBF (Mean Time Between Failures).

4.3 Highly Competitive Cost Structure

Thanks to our full industrial chain manufacturing advantage, HVC eliminates complex brand premiums and high European manufacturing labor costs.

• HVC Advantage: Under the premise of equivalent (or even better) performance, HVC's prices are typically 30%-40% lower than METALLUX's. This provides valuable cost reduction space for customers in fierce market competition.

5. Application Scenarios: Comprehensive Coverage from Medical to Industrial

The HVC HVR series has successfully replaced METALLUX in multiple high-tech fields globally, passing rigorous real-world validation.

5.1 Medical Imaging

Used as anode protection resistors in high-voltage generators of DR / CT machines. HVC's non-inductive design effectively suppresses high-frequency oscillations, protecting expensive X-ray tubes and extending equipment life.

5.2 High Voltage Test & Measurement

In high-voltage dividers, HVC's low TCR (±50ppm) and low voltage coefficient characteristics ensure measurement accuracy throughout the full range, adopted by multiple metrology institutes.

5.3 Industrial High Voltage Supply

In electrostatic spraying and dust removal power supplies, HVC's high humidity resistance and pulse withstand capability ensure stable and reliable operation under harsh conditions, significantly reducing maintenance rates.

5.4 Research & Physics

In particle accelerators and pulsed power systems, HVC's ultra-high voltage customization capability (up to 100kV) meets researchers' pursuit of extreme parameters.

6. Conclusion: Source Replacement, Peace of Mind

Faced with METALLUX's long lead times and high costs, continuing to wait is no longer a wise choice.

The HVC HVR series provides you with a zero-risk, high-performance alternative solution with German quality standards + domestic speed response. We not only provide products but also offer full-process technical support from selection and testing to after-sales service.

7. METALLUX Complete Model Quick Reference

METALLUX HVR/HPR/HVI Series complete model list (64 models total):

HVR Series - Standard High Voltage Resistors (36)
HVR967.3.25	HVR967.3.38	HVR967.5.13	HVR967.7.51
HVR967.8.26	HVR967.13.38	HVR967.15.30	HVR967.15.51
HVR967.15.76	HVR967.25.90	HVR967	HVR967.1
HVR967.28.38	HVR968.2	HVR968.3	HVR968.4
HVR968.5	HVR968.7	HVR968.10	HVR968.12
HVR968.15	HVR968	HVR969.11	HVR969.23
HVR969.54	HVR969.71	HVR969.105	HVR969
HVR22.5	HVR40050.0

HPR Series - High Precision High Voltage Resistors (18)
HPR967	HPR967.3.25	HPR967.3.38
HPR967.5.13	HPR967.8.26	HPR967.13.38
HPR967.15.30	HPR967.15.51	HPR967.25.90
HPR968	HPR968.2	HPR968.3
HPR968.5	HPR968.7	HPR968.10
HPR968.12	HPR968.15	HPR969

HVI Series - Pulse High Voltage Resistors (10)
HVI967	HVI968	HVI968.2
HVI968.3	HVI968.5	HVI968.7
HVI968.10	HVI968.12	HVI968.15
HVI969

8. HVC Part Numbering Code

HVR-[Series]-[Size]-[Resistance]-[Tolerance]-[TCR]-[Voltage]

Code	Meaning	Example
HVR	High voltage resistor prefix	HVR-GXP4.25
GXP/GFP	Flat style series	GXP=Standard, GFP=Economy
BSP/PFS	Tubular style series	BSP=Standard tubular, PFS=High power
Size	Length code	4.25, 7.52, BSP27
Resistance	100K=100kΩ, 1M=1MΩ	100K, 1M, 10M
Tolerance	F=±1%, J=±5%	F
TCR	25=±25ppm/°C, 100=±100ppm/°C	25
Voltage	12kV, 30kV, 45kV	30kV

Order Example: Replace HVR967.3.25 → HVR-GXP4.25-10M-F-25-12kV

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9. Contact and Technical Support

If you are looking for replacements for discontinued METALLUX series, or have any needs regarding high-voltage resistor selection or customization, HVC's replacement engineering team will always be available to provide support.

We promise to provide free sample testing and original manufacturer-level technical support for all replacement projects, jointly promoting the sustainable development of high-voltage technology.

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Copyright Statement: This document is owned by HVC Capacitor. Reproduction or use for commercial purposes without permission is prohibited.
Disclaimer: The technical parameters in this document are for reference only; actual specifications prevail in the latest data sheet. The trademarks METALLUX, HVR 967/968/969 mentioned in this document are registered trademarks of their respective owners and are used only for technical compatibility explanation.