Product Design

Precision-driven product design for custom magnetics. Expert engineering for tailored solutions, ensuring reliability and efficiency for your unique requirements.

Stage 7

Stage 7

Manufacture according to product BOM, production job steps and quality plan.

Stage 6

Stage 6

Customer prototype examination and approval.

Stage 5

Stage 5

Test the prototypes and qualify to specifications, review for improvements / design modifications, review of workmanship.

Stage 4

Stage 4

Develop & build pre-production prototypes as determined.

Stage 3

Stage 3

Specify the BOM and manufacturing process steps for quoting

Stage 2

Stage 2

Begin the design phase to optimize for best combination of size – performance – quality and manufacturability.

Stage 1

Stage 1

We start with component specifications and parameters relative to your equipment & application.

Stage 8

Stage 8

Compliance and Certification if requested by Customer.

Optimized Design Package
Performance / Quality / Size / Manufacturability
Improved Operational Performance
Higher efficiency, higher accuracy, cooler operating temperatures, improved functionality.
Improved Quality
Materials Selection & Substitution
Reduce size & Weight, Save valuable space, fit into available space dimensions
Protection from vibration, moisture, corrosion
Improved Manufacturability
Windings, Connections, Spacings, Insulating methods, Assembly Methods, Tolerance Considerations etc.
Meet UL & CSA Safety Standards when specified
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Reverse Engineering

Strategic reverse engineering for custom magnetics: Deconstructing and analysing to recreate or enhance custom magnetics with precision and innovation expertise.

Our Case Studies

Discover our transformative journey through diverse case studies showcasing innovation in Product Design, precision in Reverse Engineering, and expertise in Wound Component Repair. Each narrative reflects our commitment to excellence, problem-solving, and pushing the boundaries of what’s achievable in product development, technology restoration and customer satisfaction.

Typical Transformer Design Considerations

End Equipment Application Description

Power Supply Circuit Operational Requirements

Safety Standards

Dimensional Requirements & Mounting

Weight Requirements

Efficiency Requirements

Maximum / Minimum Ambient Temperature Requirements

Over Voltage / Over Current Handling Conditions

Transformatio0n Characteristics: linearity (Current, Voltage), accuracy (measurement / high accuracy, sensing / low accuracy), tolerances

Impedance Matching

Isolation Voltage Level

Voltage Regulation

EMI Shielding

Ruggedness to Vibration and Environment

Design for Manufacturability & Parts Availability for Fast Delivery

Duty Cycle

Cooling Method: Heat sink, Forced Air, Natural Convection

Encapsulation, Potting


Environmental considerations (ROHS, REACH etc.)

Typical Inductor Design Considerations

Circuit Topology

(flyback, Forward, Push-Pull, Half Bridge and Full Bridge Converter topologies etc.)

Frequency, Range of Operation


Adjustable / Tuned Inductance

Q at Test Frequency

Self Resonant Frequency

DC Resistance max

AC Current Rating, AC Ripple Current

DC Bias Current max & % drop in Inductance from Zero DC

Dimensional Constraints

Termination Specs

(terminals, leads)

Duty Cycle

Weight Requirements

Maximum / Minimum Ambient Temperature Requirements

Ruggedness to vibration environment

Encapsulation with Epoxy or Silicone

Safety Standard Requirements

(UL, CSA, etc)

MIL Spec Standards

Cooling Method: Heat sink, Forced Air, Natural Convection

Environmental Considerations

(ROHS, REACH etc.)

Leading Designer and Manufacturer of Custom Transformers, Inductors,
Windings and related assemblies



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