The first winding on the bobbin using magnet wire – coated for electrical insulation.

Applying the overwinding insulation with Mylar® adhesive tape – providing additional electrical insulation between windings.

The second winding on the bobbin – also coated for electrical insulation. The wire may be the same as the first winding, or it may not.

After the transformer has been wound and terminated to the pins, it is soldered and cores are inserted. A clamp is used to hold core halves together until cement is cured.

Once the core is inserted, the transformer is tested to ensure customer specifications are met. Every transformer is tested before delivery.

Insertion of lamination pieces, made of silicon steel, to form core of transformer. Bobbin wound transformers and bobbin wound inductors both go through this process.

Gowanda records manufacturing steps and feedback during the construction process.

Toroidal transformers ready to be encapsulated in a potting shell.

Potting (environmental sealing) will occur towards the end of the manufacturing process to protect the transformer from debris and moisture.