Transformer circular box

[xzswq21]

Hello
I want to produce 1000 transformers so I need circular or simple boxes for our transformers. the material of the box should be heat resistant bcoz I put the boxes in an Oven at 120'C,
Actually I'm thinking of a 3D printer but the material is a problem! I really don't know what I should do. Dimensions are 1"x1"x1" and I would prefer a Cylinder with a 1" diameter and a 1" height.




Thanks

[TimFox]

Carbon fiber and FR4/G10 composites are available as 1 inch diameter thin-wall cylinders.

[David Hess]

FR4/G10 composites

https://www.mcmaster.com/garolite-tubing/

FR4 and G10 are likely overkill, but Garolite is available with many compositions.  Garolite CE is cotton, Garolite XX is paper, and Garolite LE is linen.

[xzswq21]

Can I buy a 3D printer to print such shapes?

[Zero999]

It probably could be 3D printed, the problem is winding the transformer and potting it, so it doesn't arc over. It has to be wound in a careful manner, to ensure the voltage between neighbouring wires doesn't exceed 500V, or so and potted with resin in a vacuum to exclude air pockets. Everything must be kept clean and free from moisture, salt and greese.

You could even just use the box as a mould and remove it, after the potting has cured, but you need to ensure that there's enough space between the windings and the mould, so they don't poke out, when it's removed.

[David Hess]

I would be really cautious about 3D printing a form which is going to rely on potting for high voltage insulation because of air gaps inside the 3D printed form.

[xzswq21]

It probably could be 3D printed, the problem is winding the transformer and potting it, so it doesn't arc over. It has to be wound in a careful manner, to ensure the voltage between neighbouring wires doesn't exceed 500V, or so and potted with resin in a vacuum to exclude air pockets. Everything must be kept clean and free from moisture, salt and greese.

You could even just use the box as a mould and remove it, after the potting has cured, but you need to ensure that there's enough space between the windings and the mould, so they don't poke out, when it's removed.

I have a coil winder and I use cylindrical and segmented bobbin to reduce the wire insulation stress as following: plus I have a Vacuum Oven and a good electrical insulating epoxy resin, now my problem is finding a box,