America’s grid upgrade hinges on a 400-ton machine designed in the 1800s — and just one U.S. mill makes the special steel inside it

America's power grid is undergoing an upgrade that relies on a massive 400-ton machine, a design from the 1800s. Only one U.S. mill manufactures the specialized steel needed for these transformers. Large power transformers, crucial for transmitting electricity over long distances, are aging and in short supply. The manufacturing process for these transformers is outdated, taking over three years for orders to be filled.

Demand for certain types of transformers has surged, with costs increasing by 80% in just a few years. Some tech companies are bypassing the grid and installing on-site gas power plants, causing another supply chain issue. The U.S. is looking to standardize transformer designs and deploy innovative grid-enhancing technologies to address these challenges.