Product Design

Whether your project is a New Product Design, a Build-to-Print, or a Design Modification, we will be happy to assist you with your technical requirements. We collaborate with you on each of your application-specific projects to identify your key parameters to accelerate product development and improve component performance and reliability. We produce a high quality product that performs to your expectations in as short a time as possible.

Our Product Development Process ¹

• We start with your component specifications and parameters relative to your equipment & application
• Begin the design phase to optimize for best combination of size – performance – quality – manufacturability
• Specify the BOM and manufacturing process steps for costing / quoting / manufacturing
• Develop & build pre-production prototypes as determined
• Test the prototypes and qualify to specifications, review for improvements / design modifications, review of workmanship
• Customer prototype examination and approval
• Manufacture according to product BOM, production job steps and quality plan
• Compliance and Certification if requested by customer

Reverse Engineering ¹

With regards to production quantities, we are happy to take a sample of something that is close to what
you are envisioning and create a product with the appropriate adjustments and improvements for you.

Transformer Design ¹

High Frequency Transformers
Toroidal Transformers
Power Transformers
Current Transformers
High Voltage Transformers
Isolation Transformers
Potential Transformers
Audio Transformers
Pulse Transformers
Small 3 Phase Transformers
Custom & Equivalent Transformers

Inductor Design ¹

Switch Mode Inductors
Common Mode Chokes
3-Phase Inductors
High Current Inductors
Input / Output Chokes
Air Core Inductors
Power Factor Correction Inductors
DC Inductors
Custom & Equivalent Inductors

Special Winding Design ¹

Electromagnets
Sensor Coils
Antenna Coils
Custom Windings

Insulation / Safety Standards / Construction

Insulation Systems: 105°C, 130°C, 155°C, 180°C, 220°C
Safety Standards: UL, CSA as requested
Materials: selected for your desired performance / price / quality level,
RoHS compliance as required
Encapsulation: vacuum pressure epoxy encapsulation, potting, casting
Mountings: available in chassis mount, through hole mount, surface mount and custom
Terminations: available as terminals, leads, and special

Design Objectives

• Optimized Design Package – performance / quality / size / manufacturability
• Improved Operational Performance - higher efficiency, higher accuracy, cooler operating temperatures, improved functionality
• Improved Quality – materials selection & substitutions
• Compactness – reduce size & weight, save valuable space, fit into available space dimensions
• Ruggedness – protection from vibration, moisture, corrosion
• Improved Manufacturability – windings, connections, spacings, insulating methods, assembly methods, tolerance considerations, etc.
• Meet UL &, CSA Safety Standards when specified

Typical Transformer Design Considerations

• end equipment application description
• power supply circuit operational requirements
• safety standards
• dimensional requirements
• weight requirements
• efficiency requirements
• maximum / minimum ambient temperature requirements
• over voltage / over current handling conditions
• transformation characteristics: linearity (current, voltage), accuracy (measurement / high accuracy, sensing / low accuracy), tolerances
• impedance matching
• isolation voltage level
• voltage regulation
• EMI shielding
• ruggedness to vibration & environment
• design for manufacturability & parts availability for fast delivery