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Custom Transformer and Inductor Prototypes

ConverNova builds custom transformer, inductor and common mode choke prototypes from a single unit. You send the specification, we send back a design proposal usually within 24 hours, and the prototype arrives 4 to 8 weeks after the design is agreed. The prototype is built on the same drawing that later goes to production, so nothing gets redesigned when the volume arrives.

Send us your spec

How to order

Six steps, and you know where you are at every one.

01

Send your specification

Topology, electrical, mechanical and environmental. Attach CSV waveforms or specification files up to 10 MB. If the magnetics spec is not written yet, a schematic and a waveform are enough: defining it is the part we are good at.

02

Engineering answer usually in 24 hours

A power electronics engineer reads it, not a mailbox. You get a first design proposal with estimated core and winding losses, leakage and magnetizing inductance, dimensions and the expected hotspot temperature.

03

Agree the design, then the price

We adjust against your priorities: efficiency, size, cost. We tell you where the three pull against each other so the trade is yours to make. The quote follows the agreed design.

04

We build it

Four to eight weeks from the agreed design, when the required raw materials are in stock, with progress updates along the way. If a material is on long lead we say so on day one rather than at week six.

05

Measured, then shipped

Each part is measured for inductance, leakage inductance and DC resistance, and ships with a test report.

06

And then production

Same design, same drawing, same materials, same people. Nothing gets redesigned when the volume arrives, and we have been looking at manufacturing cost and DFM since day one.

What arrives

A part, and the numbers behind it.

The report is not an extra. It is how you close the loop between your simulation and your bench.

Send us your spec
Measured
Inductance, leakage inductance, interwinding capacitance and DC resistance, at your switching frequency
Loss split
Core loss and winding loss separately, so you know which one to attack if you need more efficiency
Thermal
Temperature rise under your real waveform and your cooling method, with the hotspot location
Dimensions
Measured dimensions against your drawing and keepout, so you know it fits before it reaches your board.

Construction

From prototype to production.

The same construction from the first unit to the series, which is why nothing gets redesigned when the volume arrives.

A transformer encapsulated in a case on a mounting plate
A row of varnished transformers on a mounting rail, lead terminated
A housed magnetic assembly with one AC input and two DC output glands

Straight answers

Prototypes, the usual questions.

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.
What is your minimum order?
One. Most of our first projects start as a single unit and a problem nobody else wanted to look at.
Do I pay for the design?
The engineering review and the first design proposal are free. You see the loss distribution and the parameter values before you commit to anything. More on our custom magnetics design process.
Will the production part be the same as the prototype?
Yes. Same design, same drawing, same materials, same people. That is the point of designing for manufacturing from day one instead of at the end.
We are a small team. Are we too small for you?
No.
Can you go faster than four weeks?
Sometimes. When the core and wire are in stock, a first sample can ship in two to four weeks, occasionally with a compromise we agree with you first. See Fast Samples.
What information do you need to start a prototype?
Topology, switching frequency, voltages, currents, isolation and the space you have. If the specification is not written yet, a schematic and the waveforms are enough.

Start here

Send us your spec.

Or just the schematic and the waveform. Engineering answer, we aim for 24 hours.

Send us your spec