Stress calculation is a key link in evaluating whether the structure of a superconducting magnet is safe. A 35-kV/3.5-MVA single-phase high temperature superconductivity-controllable reactor (HTS-CR) with the HTS winding wound by HTS double pancakes is being developed. The effect on the local stress and temperature rise of HTS double pancakes, which determines the design of the strengthening structure of the HTS double pancake, is studied in this paper. Furthermore, the multiprocess stress development for HTS double pancakes from manufacturing to power-on is also investigated, which discloses the model and the results of the stress calculation. This study can provide a reference for developing HTS-CR with large capacity in the future.