new to this project and have limited knowledge, but the failure is consistent thru all specimens so I am hoping someone could shed some light. Film cap design is rated to 1650v Failure- Cap initially failed around 800v consistently, the curing time was adjusted and a ramping cycle was introduced to ramp up temp and down temp and peak curing temp is now held for 9 hours and max voltage reached has increased to two groups, many failures in the 1500 range and then about the same amount reach the 1800v range before failure. Failure occurs in the top layers and shows damage inward about 1/4" inch (overall diameter is approx 3.1") Adjusting the curing process gives me significantly better results, does this sound like a curing issue? Also due to be noted that the failure always seems to occur 3/4" clockwise from the stitching and then runs parallel to it from end to end. Failure looks like bubbly marks or acne on your skin, then when the layers are pealed back you can see the depth of the failure. It is not a dielectric failure. Just purchased a new high speed film winding machine, and film tension is set to around the 650 range, Could this be a process issue? Is an adjustable tension setting needed when winding? I am wondering if my top layers are not being wound tight enough and various air gaps are being introduced. Or could this be a curing issue? Noticed the substantial different in my results when my curing times were adjust from a straight single temperature curing time to an adjustable ramping setting. Any input or thoughts would be appreciated, very new to the making of film caps.