Design & Capability
Engineering that starts from your specification.
⭐ New bobbin development & rapid prototypes
Our team has launched many new bobbins, from design and material choice to tooling and first articles. For fast samples we 3D-print prototype bobbins and ferrite-core prototypes, so you can check fit and build early samples before tooling is cut.
⭐ Bobbin-less construction with Nomex tape
Transformers and inductors wound directly on Nomex insulation tape without a bobbin: more copper in the window, better cooling and high-temperature (Class H) insulation, a rare skill in Indian magnetics manufacturing.
Match any existing part
From its inductance and DC resistance we iterate across our vendors' core database until a single core matches inductance, resistance, weight and self-resonant frequency.
Design from first principles
Turns from operating conditions, then copper and core losses, surface area and temperature rise, iterated until the target rise is met.
In-house design software
Our own home-grown tools for designing common-mode chokes and inductors: core selection, turns, losses and temperature rise in minutes instead of days.
High-frequency winding design
We design for skin depth and proximity losses, choosing between solid, Litz and flat (rectangular) wire, and we design and build flat-wire windings for high-current, low-loss magnetics.
Insulation materials expertise
Teflon (PTFE) tape, which few Indian magnetics makers use; Teflon, fibreglass and silicone sleeving; triple-insulated (TIW) and polyamide-coated Litz wire for reinforced insulation and safety approvals.
Temperature-rise mastery
Every design is checked for core and copper losses against the target rise and the insulation class, so parts run cool and last.
UL insulation systems
We understand UL-recognised insulation systems and material approvals and design to them from day one, as our customers in the USA require.
Global customers
Long-running programmes with several US-listed multinational companies (names withheld for confidentiality), plus leading Indian brands.
Redesign onto available cores
LLC and flyback designs moved to existing, slightly larger or smaller cores (Ww, Wb, Ac); equivalents of standard catalogue CMCs and flyback transformers from the specification alone.
Materials sourcing
Direct relationships with manufacturers in China, in daily contact on WeChat, plus a strong network in India for cores, bobbins and headers; local plastic tooling in FR50/FR530.