Custom Transformer Engineering
Advanced Magnetics Design provides custom transformer engineering, practical transformer designs, and documentation for customers who need a real part that can be reviewed, quoted, prototyped, built, and tested.
Design Focus
The work is focused on custom transformer engineering and design projects where the customer needs a formal transformer specification and drawing package, not just a theoretical calculation. Projects may involve a new transformer requirement, an obsolete or hard-to-source replacement, a failed prototype, incomplete supplier documentation, or a design that works electrically but is difficult to manufacture reliably.
Typical transformer work includes high-frequency switching transformers, flyback transformers, forward converters, push-pull, half-bridge, full-bridge, high-voltage transformers, isolation transformers, multi-output transformers, toroids, autotransformers, low-frequency laminated transformers, and hard-to-source replacement transformers.
For a more focused explanation of DCM flyback design tradeoffs, see the Flyback Transformer Design page.
Supported Work
Support can include new custom transformer engineering, design review, replacement documentation, or troubleshooting for converter transformers and specialty magnetic components.
Support can include high-frequency transformer design for flyback, forward converter, push-pull, half-bridge, full-bridge, LLC, resonant, high-voltage, isolation, multi-output, gate-drive, current-sense, low-frequency, laminated, and toroidal transformer applications.
Projects can include custom transformer replacement, obsolete transformer replacement, second-source transformer design, transformer reverse engineering from samples, missing winding data, material-list recovery, winding specifications, drawing packages, and manufacturing documentation.
Review work can address transformer overheating, saturation problems, failed hipot, insulation failure, excessive leakage inductance, buzzing noise, high excitation current, thermal issues, prototype failures, and production variation.
Related work can include custom magnetic component design, custom inductor design, choke design, common-mode choke support, current transformer review, and practical magnetics engineering for power-conversion equipment.
Transformer Design FAQ
Useful starting information includes input voltage range, output voltage and current, power level, frequency, topology, duty cycle, isolation or hipot requirements, temperature limits, size limits, mounting or termination needs, and any existing drawings, samples, or test data.
Yes. I provide buildable transformer specification/drawing packages suitable for quoting, prototyping, and production review. These may include electrical requirements, schematic details, mechanical dimensions, markings, material list, winding information, wire/foil/litz/insulation details, polarity, hipot requirements, test limits, and manufacturing notes.
Yes. I can support custom transformer design and review for common power-converter topologies including flyback, forward, push-pull, half-bridge, full-bridge, LLC, resonant, and other specialty transformer applications.
Yes. I can review the design, construction, operating conditions, and test results to help identify likely causes such as core saturation, excessive loss, insulation weakness, winding issues, application mismatch, or production variation.
Yes. I can help develop replacement or second-source transformer documentation using available customer requirements, existing drawings, test data, or physical samples. Exact duplication of unknown proprietary materials may require engineering judgment or supplier confirmation.
Boundaries
Advanced Magnetics Design can support magnetic-component design, documentation, testing requirements, troubleshooting, and manufacturability review. Final safety certification, agency approvals, UL/CE approval, full product design, full power-supply design, PCB design, final production validation, and production release remain with the customer or manufacturer unless separately agreed.
For replacement or reverse-engineering work, exact duplication of unknown proprietary materials or processing cannot always be guaranteed. The work can document construction and measured behavior, recommend practical design paths, and identify the engineering judgment needed to move toward a reliable buildable component.