Custom Transformers
High-frequency, planar, pulse and isolated. Built around your topology, whether that is an LLC, a phase shift full bridge, a dual active bridge or something you have not named yet.
4 to 8 wks
To prototype
ConverNova / Magnetic Design & Production
Custom magnetics for next-gen Power Converters.
Designed around your operating waveforms, and measured against them.
ConverNova designs and manufactures custom transformers, inductors and common mode chokes for power electronics. Rather than pulling the closest part from a catalog, we wind in litz, planar or foil to suit your switching frequency, and engineer the core geometry around your efficiency target while holding saturation margin at worst-case load and temperature. Each unit is then varnished or potted in aluminum to hold up against heat, shock and years of thermal cycling. First prototypes in four to eight weeks, from a single unit.
No MOQ
From one unit
24 h
Engineering answer
50 Hz to 2 MHz
Frequency range
0.03 mm
Finest litz strand
What we build
Three families. One Way of Working.
Every magnetic design starts from your topology, your waveform and the space you have, and ends on a test report with real numbers measured at your operating conditions.
Custom Inductors
Power, output filter and resonant inductors. Designed using ferrite, powder, amorphous, nanocrystalline, electrical steel and more, with core geometries optimized to balance power density against total power loss.
Common Mode Chokes
For the EMI test you would rather pass the first time. Sized from your real noise spectrum, not from a rule of thumb.
Windings
Litz, Planar, Foil.
Optimally wound for your frequency, not pulled from a catalog. Above a few hundred kilohertz the winding stops being a detail and becomes most of the loss.
Send us your spec- Litz
- From 0.03 mm strands. Strand diameter and count chosen from your switching frequency and your harmonic content, so the copper is used instead of just heated by skin and proximity effect
- Planar
- On your PCB or on ours. Very repeatable leakage inductance and a low profile, which is why it wins in tight stacks above roughly 200 kHz
- Foil
- Ideal for high-current designs requiring few turns. Offers minimal DC resistance (DCR) and a direct thermal conduction path out of the winding stack, provided inter-layer interleaving mitigates parasitic high-frequency losses.
- Triple insulated wire
- Enables fully compliant reinforced isolation without margin tape, maximizing copper fill factor within the available winding window.
- Edge wound flat wire
- High current with a high fill factor and tight bends, for chokes where every millimetre of window counts
- Round magnet wire
- Still the right answer at line frequency and low ripple. Not everything needs litz, and we will tell you when it does not
Cores
Engineered core geometry.
Maximum efficiency, zero saturation risk. Material and geometry are one decision, not two, and when no standard geometry fits we machine one.
Ferrite
The lowest core loss at high frequency, which is why it dominates switching magnetics. It saturates hard, so the gap and the peak current have to be designed together. Ferroxcube and TDK.
Nanocrystalline and amorphous
Very high permeability and high saturation flux density. The right tool for common mode impedance and for high current chokes where ferrite would need to be enormous. VAC and Hitachi.
Powder
A distributed gap through the whole core. Soft saturation and graceful overload with no fringing hotspot next to the winding, paid for in core loss. Magnetics and Micrometals.
Where a standard shape wastes window or forces a compromise on height, we machine a custom core and build the production tooling for it, so the geometry that wins the prototype is the geometry that ships.
The difference
The Nominal Point is Just a Snapshot.
We Design for the Full Spectrum. A datasheet figure is measured at one current, one temperature and one small signal. Your converter runs at none of them.
Send us your spec| What you are choosing | Catalog part | ConverNova custom |
|---|---|---|
| Core geometry | Whatever the catalog stocks | Chosen for your window, your losses and your height |
| Winding | One wire for every frequency | Litz, planar or foil, picked for your ripple and skin depth |
| Inductance | A single nominal figure | Your value, held across your operating range |
| Losses | Not published, or at one test point | Core and winding split, at your waveform |
| Leakage inductance | Uncontrolled | A design target, measured and reported |
| Footprint | Fits if you are lucky | Designed to your keepout and your mounting |
| Thermal | An ambient rating | Hotspot estimate for your cooling method |
| When the spec moves | Buy a different part and requalify | Same drawing, one revision |
The saving is not only on the unit price. It is on the efficiency point you hit, the board area you free, the requalification you do not have to run, and First-Pass Success avoiding iterations.
Construction
Varnished or potted in aluminum.
Immune to heat, shock, and time. How a magnetic is finished decides whether it survives the application, and it is designed with the part rather than chosen after it.
- Varnish
- Dip and bake, for parts that need the turns locked against vibration without the mass and the thermal expansion of a full pot
- Vacuum impregnation
- Resin drawn into the winding under vacuum, which removes the voids where partial discharge starts. The right answer when the isolation is the specification
- Potting
- Silicone, epoxy, polyurethane and resin. Chosen for the thermal path you need and the expansion the part can tolerate over its temperature range
- Aluminum housings
- Machined and marked, with the mounting and the thermal interface designed into the part rather than bolted on afterwards
- Bobbin or bobbinless
- A bobbin buys repeatability and creepage. Going without buys window area. Which one wins depends on your isolation and your fill factor
- Terminations
- Pins, flying leads, blade terminals, bus bars and PCB mounting, to your pinout and your keepout
- Qualified for
- Vibration and shock profiles, thermal cycling, humidity and altitude, to the standard your application answers to
Co-engineering
We design with you, not for you.
Most projects start with a schematic and a question.
Send us your spec01
Send the spec. Or send the problem.
A schematic and a waveform are enough. We are power electronics engineers before we are a magnetics shop, so we can read your converter, not just your drawing. If you do not have a magnetics spec yet, that is normal, and it is the part we are good at.
02
You get engineering back, not a price.
We aim for 24 hours. A first design proposal with detailed loss distribution and parameter values, so you can judge the design before you judge the quote.
03
You get the numbers.
Measured inductance, measured leakage, DC resistance, loss split, temperature rise, and the test report. Not a part in a bag.
04
One unit, or forty million.
The same design, the same drawing, the same materials, the same people. Nothing changes from samples to mass production. We look at manufacturing and cost saving from day one.
Construction
The constructions we build.
Bobbin and bobbinless, taped, varnished, potted in resin or closed into an aluminium housing. The construction follows from what the part has to survive, not from what is quickest to wind.
Sectors
Where our parts run.
Automotive and EV
On board chargers, DC-DC, traction auxiliaries. AEC-Q200 qualification path.
Renewable energy
MPPT stages, grid tie inverters, electrolysers and energy storage.
Charging, transport and SST
Fast charge stacks, solid state transformers, fuel cell converters.
Aerospace and defense
MIL-STD-981, MIL-PRF-27, DO-160. Minus 55 to plus 125 degrees C.
Pulsed power and big science
Pulsed systems, high current magnet supplies, klystron modulators and RF stages.
Medical and industrial
Isolation to medical creepage, drives, welding, and the efficiency point you have to hit.
Straight answers
The questions engineers actually ask us.
Do you build to print, or do you design it?
Whichever your project needs. If you already have a working design, send us the
drawing and we produce it. If you do not, we design the optimal magnetic for you: optimal in
efficiency, in performance and in cost, and we tell you where those three pull against each
other so the trade is yours to make.
What design information will I get?
Estimated core losses and winding losses, leakage inductance, magnetizing
inductance, dimensions, and the expected hotspot temperature. That is what arrives with the
first proposal, and we aim for inside 24 hours, before you have spent anything.
Can you hit a leakage inductance target?
Yes. And we will tell you honestly when the target fights the isolation you also
asked for. Interleaving, winding order and the bobbin all move it. We measure it and put the
number on the report.
Do you measure at my switching frequency, or at 1 kHz like the datasheets?
At yours. Tell us the switching frequency and the waveform, and those are the
conditions on the report. A number measured where you never run is not a number, it is a
decoration.
What is your minimum order?
One. Prototypes, samples and production come off the same drawing, so nothing
gets redesigned when the volume arrives.
How fast is a prototype, really?
Four to eight weeks from an agreed design, if the required raw materials are in
stock, and we aim to have the engineering answer with you inside 24 hours. When your schedule is tighter, say
so and we will tell you what is actually possible instead of what you want to hear.
We are a small team. Are we too small for you?
No. Most of our first projects start as one unit and a problem nobody else
wanted to look at.
Start here
ConverNova: Your competitive advantage in power magnetics.
Transformers, inductors, CMCs. Co-engineered with you. Prototypes in 4 to 8 weeks. No MOQ. Send the frequency, power, voltages, isolation and the space you have, or just the waveform and the problem.