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- This paper presents development of solid core suspension disc insulators (cap and cap suspension disc insulator) for replacing cap and pin suspension disc insulators in overhead transmission and distribution lines which expose to lightning discharges. By this means the punctured problem caused by steep front surge voltage created by lightning discharge on the lines can be solved. The solid core suspension insulator was designed and constructed based on the dimensions of conventional suspension disc insulators (cap and pin insulators). The insulators are made of alumina porcelain. The electrical and mechanical characteristics of the solid core suspension insulators were carried out. The puncture test was performed in the air by applying steep front impulse voltage with amplitude about 2.5 per unit of 50% flashover (CFO) of the insulator unit at negative standard lightning impulse 1.2/50 s with steepness up to 9200 kV/s. The testing results show that solid core suspension disc insulators are not punctured eventhough the steepness of the steep front impulse voltage was increased up to 9200 kV/s.