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

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

1. Product Design & Development and Reverse Engineering are not stand-alone services but integral with our product manufacturing.