Owing to the advantages of wire explosion process in synthesizing the nanoparticles, its automated design is developed for mass production of high purity and size controllable metal nanoparticles. The particle characterization methods such as TEM, XRD and EDS are utilized to demonstrate the qualitative description of produced particles at different numbers of explosions. The microstructural, thermal, mechanical, and electrical characteristics of aluminium nanoparticles in epoxy polymeric insulating materials at various filler concentrations were investigated. The charge trap features of composite materials are described in detail for different voltage polarities and ageing conditions. The space charge characteristics of composite materials are investigated under normal and polarity reversal conditions.