A detailed discussion of the design and manufacture of reliable high-energy-density pulse-discharge capacitors is presented. Electrical design and thermal analysis of single sections are described and illustrated with actual test data. The physics of failure of high voltage capacitors is explored, and its application to the design and manufacturing process displayed. A unique winding method allowing the direct fabrication of fiat sections without mechanical flattening is described. Modified drying and impregnation cycles that produce wrinkle-free sections with oil resistivity above 2 X 1015 \Omega ·cm are given. Life and energy density data from full pulse-forming network (PFN) pulse tests and from simulated PFN tests show 550 J/kg (250 J/lb) at 250 pps.