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As renewable energy systems advance, they place new demands on internal components. Nowhere is that more evident than in magnetics. Transformers and inductors are expected to perform reliably across temperature extremes, switching harmonics, and tight packaging constraints.
Solar, wind, and energy storage applications introduce unique technical challenges where off-the-shelf components may not be the best choice for system designers.
Custom magnetics, designed specifically for these applications, can help address these challenges at the earliest stages of system design. By considering unique environmental factors, high-frequency switching, thermal cycling, and system integration requirements, custom solutions can minimize the risks associated with reliability and performance.
This post explores the unique challenges magnetics face with respect to solar, wind, and battery systems—and how custom component design supports long-term reliability and system success.
Modern solar inverters are among the most demanding environments for magnetics. Central inverters at utility scale operate at high power levels with aggressive efficiency targets. String inverters and module-level devices often experience rapid changes in operating conditions, especially with passing clouds or fluctuating demand.
Switching frequencies above 50 kHz are common, introducing thermal stress and requiring magnetic cores that can operate efficiently at elevated temperatures. Standard potting compounds and windings may not hold up under these conditions, leading to premature failure.
Grid-connected solar systems must follow strict rules for harmonic distortion (THD). However, high-frequency switching tends to generate harmonics that need to be suppressed before they reach utility infrastructure. Standard magnetics may struggle to attenuate these signals effectively.
Custom magnetics can be tailored for:
Reduced core losses at high frequencies
Improved isolation distances to minimize EMI coupling
Winding techniques that balance capacitance and inductance
String inverters and rooftop-mounted devices are typically housed in compact enclosures. Limited airflow and outdoor exposure increase the risk of thermal buildup and moisture ingress. Off-the-shelf parts, often designed for controlled indoor use, may degrade quickly in such environments.
Custom solutions can:
Include encapsulation for humidity resistance
Utilize thermally stable winding materials
Be shaped for non-traditional footprints (e.g., vertical mount designs)
Wind turbines, particularly offshore and high-capacity units, present unique magnetic challenges. Generator systems can produce rapid current fluctuations, especially during startup or changes in wind speed. Inductors and transformers must be able to manage high inrush currents without saturating.
Where off-the-shelf inductors might saturate under these loads, custom components can be designed with:
Controlled saturation profiles
Distributed air gaps for smoother magnetic response
Core materials selected for high permeability and low loss
Wind turbines put magnetics in tough conditions. Their nacelles are high off the ground and constantly vibrating. Standard inductors may fail due to mechanical fatigue or resin cracking.
Custom magnetics for wind applications often include:
Reinforced bobbins and windings
Vacuum encapsulation for vibration dampening
Mechanical mounting features integrated into the component design
Variable-speed wind turbines often inject harmonics into the local grid, affecting other systems nearby. Custom filter inductors can be tuned to specific harmonic ranges to reduce these effects before they propagate.
Battery energy storage systems (BESS) require magnetics that can handle power flow in both directions—charging and discharging. This introduces different waveform shapes and current intensities, which many single-direction magnetics are not optimized for.
Custom transformers and inductors in this space are built to:
Maintain consistent inductance across polarity changes
Handle transient loads without distortion
Provide isolation under both charge and discharge conditions
Energy storage systems are often housed in sealed containers with limited airflow. Passive thermal management becomes essential. Custom magnetics help by minimizing internal heat generation through efficient core materials and winding layouts.
Strategies include:
Using core materials with low hysteresis and eddy current losses
Selecting winding techniques that reduce hot spots
Designing for natural convection pathways within the enclosure
Battery systems must maintain galvanic isolation, even during fault conditions. This requires insulation systems that hold up during thermal events or voltage surges. Custom magnetics can incorporate high-grade insulation and layout spacing that meet specific isolation standards.
Custom doesn’t just mean different. It means built with purpose. The value lies in:
Predictable thermal behaviour: Helps avoid derating and ensures consistent performance across temperature swings.
Consistent impedance and response: Reduces distortion and improves controller feedback accuracy.
Optimized footprint: Makes the most of limited enclosure space.
Environmental resilience: Withstands vibration, moisture, and thermal shock better than general-purpose parts.
These advantages often lead to:
Fewer field failures
Lower maintenance intervention
More consistent performance over product lifetime
While custom magnetics may involve longer lead times and validation steps, they mitigate the much higher cost of failure in mission-critical renewable applications.
Understanding the true impact of magnetic component failure helps justify the investment in custom solutions. Industry reports indicate that offshore wind component failures can result in multi-million-dollar replacement costs, particularly when specialized vessels and equipment are required.
According to a T&D World analysis on transformer resiliency, "the largest transformer loss on record occurred at a power plant, resulting in business interruption costs of more than $86 million" as reported by Willis Risk Solutions. The article emphasizes how transformers face electrical, thermal, and chemical stresses that can degrade insulating oils and lead to premature failure, highlighting why custom designs with enhanced durability are critical for renewable energy applications.
For solar installations, inverter-related failures average tens of thousands of dollars in physical damage alone, with business interruption costs often doubling that figure due to extended repair times. Research indicates that offshore wind turbines experience multiple failures annually, with major component replacements running into significant costs even before considering downtime.
Consider these hidden costs:
Emergency service calls to remote installations
System downtime during peak production periods
Warranty claims and customer satisfaction issues
Regulatory penalties for grid non-compliance
Reputation damage in competitive markets
Custom magnetics represent a strategic investment that prevents these cascading failures. While custom components cost more initially than standard catalogue parts, the investment becomes justifiable when compared to the potential failure costs and risk mitigation achieved.
Working with an experienced custom magnetics partner means identifying risks early. During the design phase, key considerations include:
Voltage and current range across all operating conditions
Target switching frequency and any harmonic constraints
Ambient and internal temperature profiles
Mechanical stress and vibration profiles
Size and shape constraints from system layout
Early prototyping and testing ensure that magnetics behave as expected under real-world conditions. Testing can include:
Partial discharge detection
Thermal imaging under load
Dielectric strength testing
Accelerated thermal cycling
Renewable energy systems demand high repeatability. Custom magnetics often require:
Precision winding (foil, toroid, rectangular)
Automated electrical testing (e.g., Voltech systems)
Vacuum encapsulation for environmental sealing
Ferrite core grinding for inductance tuning
Quality-focused manufacturers also offer:
Documentation for traceability
Lot-specific test reports
This level of control cuts down variation between batches. That’s key when you need identical performance in every unit.
A few key trends are shaping the future of magnetics in renewable energy:
Wide-bandgap semiconductors (SiC, GaN): Require magnetics that operate efficiently at MHz-level frequencies.
Digital monitoring integration: Sensors embedded into magnetics for predictive maintenance.
Modular magnetics designs: Enabling easier servicing and replacement.
Sustainable materials: Including recyclable cores and low-impact potting compounds.
Engineers are increasingly looking at magnetics not as standalone components but as part of an optimized power system. That system-level thinking drives more demand for custom designs.
Custom magnetics are not just about fit and form—they’re about risk management. In renewable energy systems where uptime, safety, and performance are all critical, the cost of guessing wrong is too high.
Working with experienced engineers from the outset allows teams to identify failure modes early, test more effectively, and build in confidence from the ground up. From the heat of a rooftop inverter to the vibration of a nacelle, well-designed magnetics can make the difference between a product that performs—and one that fails prematurely.
The challenges are real, but so are the solutions. And in a space where every watt counts, solving them starts at the core.
When renewable energy systems face unexpected failures or standard magnetic components limit design flexibility, the root cause often traces back to components that weren't built for these demanding applications. Electronic Craftsmen specializes in solving exactly these challenges.
Our engineering team has developed over 10,000 custom magnetic solutions across six decades. From high-frequency transformers that thrive in desert heat to inductors that withstand offshore vibration, we've tackled the toughest renewable energy applications.
Don't let magnetic component limitations hold back your renewable energy innovations. Schedule a consultation with our engineering team to discuss your specific challenges. We'll analyze your requirements, share insights from similar projects, and develop a custom solution that ensures long-term reliability.
Not all transformer core material performs the same, and the wrong choice can compromise your magnetics design. Core material affects how a transformer performs under load, how hot it gets, how much space it occupies, and even how much it costs to build and run.
While windings and insulation often get the spotlight, the core is doing the heavy lifting behind the scenes. It handles the magnetic energy flow, and the way it does that depends entirely on the material you choose.
This post looks at why transformer core material matters. You'll see how it impacts efficiency, size, and cost—and how the right expertise can help you pick the optimal material from the start.
At the heart of every transformer is the core. It's responsible for the transfer of magnetic energy through the magnetic device. The better the material at handling this transfer of power, the more efficient the device operates.
Every core material behaves differently. Some materials are better at high frequency switching than others (i.e. ferrite). Each one comes with its own limitations and drawbacks as it pertains to heat rise, signal distortion, and energy loss.
When the core material precisely matches the application, everything works better. As efficiency increases, losses go down. Size and weight are easier to control but when the material isn't a good fit, systems can run hot, lose power, or require larger parts to hit the same performance levels.
That’s why engineers spend time on magnetic core selection early in the design process—it’s one of the most critical choices in magnetic components.
Core material has a direct effect on how much energy your transformer uses—and how much it wastes. As current moves through the transformer, part of it turns into heat. Some materials hold that loss a minimum…others don't.
Ferrite, for example, performs well at high-frequencies and keeps energy losses low. Silicon steel is more rugged and works better at low frequencies, though it loses more power to heat. Powdered iron sits somewhere in the middle, offering balance between performance and strength.
Access to thermal modelling and performance testing early in the design process helps teams choose materials that keep losses low without risking overheating.
Core losses happen in two main ways: hysteresis loss and eddy current loss. Hysteresis loss occurs as the magnetic field repeatedly changes direction, creating friction at the molecular level. Eddy current losses happen when small electrical currents form within the core material itself.
Different materials combat these losses in different ways:
Silicon steel uses thin laminations to break up eddy currents
Ferrite naturally resists eddy currents with high electrical resistance
Powdered iron uses tiny, insulated particles to minimize both loss types
Nanocrystalline cores offer exceptional performance but at higher cost
Matching these properties to your specific frequency and operational range and duty cycle is crucial. But isn't a high-performing core always better? Not necessarily. Some applications might not justify the cost of premium materials if the efficiency gains aren't critical to the design requirements.
Different materials handle magnetic energy in different ways. That affects how large your magnetics need to be. Some high-performance materials allow for smaller core shapes because they hold more energy in less space. That's why ferrite and high-flux cores are common in aerospace and electric vehicle systems, where every gram matters.
In certain instances, size might be less critical, so designers might choose more affordable but heavier materials like laminated steel.
Material costs vary. Some are more expensive to shape. Others are harder to find. The right choice depends on your budget, timeline, and performance needs. Ferrite may cost more upfront, especially for custom shapes. But it can also reduce long-term energy loss and system heat.
Powdered cores are often easier to source and machine. Laminated steel is cost-effective for basic low frequency uses but less efficient over time. Working with vendors that offer a range of options helps teams avoid long delays or overspending on overbuilt designs.
The perfect core isn't just about electrical performance—it needs to physically survive its operating environment. Some materials offer excellent magnetic properties but poor mechanical strength.
Core materials must withstand:
Mechanical vibration and shock
Thermal cycling and expansion
Installation stress during winding and assembly
Environmental factors like humidity and corrosion
Ferrite is often recommended for high-frequency applications where electromagnetic interference (EMI) is a concern. But when mechanical durability matters more, encapsulated powdered iron cores can handle rougher conditions without cracking.
Precision machining helps teams meet tight specifications without overbuilding. This is particularly valuable for ferrite cores, where small adjustments to the physical dimensions can dial in exact inductance values without compromising performance.
Every industry comes with its own design constraints—and each one depends on the right core material to meet performance, safety, and cost goals. At Electronic Craftsmen, we support a wide range of applications, from aerospace to automation. Explore the industries we serve.
In aerospace systems, size, weight, and reliability are everything. Transformers often need to perform under high-vibration conditions and within tight thermal limits. That means using materials like ferrite, which can support high frequency switching in a compact footprint. Additionally, Electronic Craftsmen offers In-house ferrite grinding so designers can precisely meet stringent component requirements.
Lastly, our transformers are constructed to meet the requirements of standards such as MIL-PRF-27 for added reliability in demanding conditions.
In communications gear and high-frequency power systems, signal clarity and thermal stability are key. That's where ferrites and powdered iron cores often shine. These materials support faster switching speeds with fewer electromagnetic losses.
For low frequency applications such as in industrial and automation systems, Laminated steel magnetics are widely used. However, these components may be subject to environmental challenges such as high humidity, extreme temperatures, and industrial contaminates. Features like vacuum encapsulation, antifungal coatings, and epoxy coatings protect core materials in extreme conditions.
Transformer cores in renewable energy systems face unique challenges. Solar inverters, wind power generators, and energy storage setups all demand high efficiency core materials to make the most of limited energy capture—often while operating outdoors or in variable conditions.
For solar inverters, the core must support frequent load changes as sunlight shifts throughout the day. This dynamic environment favours materials with low hysteresis loss that can maintain performance across thousands of magnetic cycles. Ferrite and amorphous cores often fit the bill, offering solid efficiency at a reasonable cost.
Wind power adds another layer of complexity. These systems operate at variable frequencies and can face mechanical vibration that stresses brittle core materials. Cores need to handle that strain while staying efficient across changing electrical loads.
In EV charging and battery storage, transformers often use nanocrystalline or powdered metal cores. These materials support high-frequency switching while keeping transformer size compact—a key factor in modern power systems.
Thermal management is especially important in green tech, where transformers may be enclosed with limited cooling. Core materials that naturally run cooler help maintain efficiency in hot weather and extend system life.
We design custom magnetics for renewable energy with a focus on efficiency, temperature stability, and long-term reliability—helping your systems produce maximum power with minimum waste.
Choosing the right core material isn't just about specs—it's about solving a system-level challenge. That's where specialized magnetics manufacturers make the biggest impact.
Instead of guessing which material will work, you need hands-on support with electrical modeling, thermal simulations, and prototype testing. These tools help compare options based on actual performance, not just datasheets.
At Electronic Craftsmen, we offer in-house ferrite core grinding. That means parts can be built to tight inductance specs without needing a full layout change. This is especially useful when space is limited or when weight must be minimized without losing performance.
With both domestic and offshore vendor relationships, we source a wide range of materials—while still doing final testing and assembly in Canada to ensure quality. Whether your goal is cutting size, improving efficiency, or staying within budget, our team helps you design with the right material from the start.
Choosing the right core material doesn't just fine-tune your transformer—it shapes your system's future. From thermal losses and switching frequency to footprint and compliance, the core plays a central role in performance and cost.
That's why teams across aerospace, green energy, and industrial automation trust Electronic Craftsmen to help them make the right call—combining deep material knowledge with collaborative design support. Reliable magnetics don't just move current—they move your project forward.
Ready to optimize your next transformer design with the right core material?
Contact us today for expert guidance on your custom magnetic components.
Your product design hits a roadblock. The perfect magnetic component doesn't exist—at least, not off the shelf. For engineers and product designers, this challenge is all too familiar. Selecting the wrong magnetic components can lead to performance issues and additional cost that can affect your bottom line.
As North American manufacturing grows again, companies must find new ways to compete with offshore pricing pressure. The pressure to innovate faster while reducing costs forces difficult trade-offs. Engineers often find themselves choosing between design compromises, extended timelines, or budget overruns. This balancing act becomes even more challenging when standard components fall short of performance requirements.
Time and cost matter more than ever in product development. Companies need to make smaller, better products faster while staying profitable. This is where custom magnetic components can give your product a real edge in the market. Choosing between custom and standard magnetic parts affects everything—from how you design to how customers use your product.
Product development cycles move faster today, so each design choice matters more. When you work with custom magnetic component makers, you get expert help that makes your designs better from the start. This teamwork transforms what could be just a components decision into a strategic advantage for your product's future. Engineers who understand this partnership gain more reliable products, superior performance, and greater market longevity.
Engineers often pick standard parts to save money upfront. This makes sense during early budgeting. But this approach can force design changes that cost more in the end. Getting standard catalog parts can also be tricky.
Supply chains for off-the-shelf parts can be unpredictable, causing surprise delays. These delays can throw off your product schedule and slow down your market launch.
Standard components rarely fit perfectly in your unique design. When engineers are required to fit “square components into round holes”, they are often forced to:
Redesign circuit boards for larger component footprints
Add cooling solutions for parts that run too hot
Install extra shielding to block electromagnetic interference
Create special brackets or mounts
These changes waste time and money, and they add to the overall complexity of the PCB (Printed Circuit Board) or cabinet design.
Using standard magnetic components that aren't finely tuned to your specific needs may result in energy waste in addition to thermal and reliability issues.
Efficiency is always a design consideration in any application; even small percentage improvements can make a significant difference. In power-hungry products like industrial equipment or electric vehicles, efficiency gaps translate directly to energy costs over the product's lifetime. Custom designs convert energy more efficiently, improving system reliability and operational costs.
Custom magnetic compone nts are built to match your exact size needs and packaging limits. Custom connection points make assembly easier and more durable, cutting production time and warranty claims.
With today's push for smaller products, space really matters. Custom transformers and inductors can be sized just right for your needs, often smaller than standard options. This gives your product an edge through better use of space.
Custom transformers and inductors are designed to meet your exact voltage, current, and frequency requirements. A custom design will create optimal power transfer ratios, impedance matching, and frequency response for your specific application.
Custom magnetic components deliver only the electrical performance your application needs—no more, no less.
Duty cycle refers to how long a component remains active within each operating cycle, typically expressed as a percentage. A 60% duty cycle means the part is in operation 60% of the time and idle the other 40%. In magnetic components, a larger duty cycle generates more heat and increases electrical stress—especially in high-current or fast-switching environments.
This is where standard components can struggle. They’re not built around your specific operating profile or thermal requirements. Custom inductors and transformers from Electronic Craftsmen are engineered for your exact duty cycle—reducing core losses, managing heat more effectively, and improving long-term reliability under real-world conditions.
When you work with custom magnetic component makers, you get valuable design expertise and material advice. These expert engineers can suggest solutions you might not have thought of.
Partnering with skilled engineers ensures better performance and reliability. Many custom manufacturers also offer quick prototyping and testing, which reduces risks and gets your product to market faster.
Custom magnetic components offer another big advantage: they can adapt as your needs change. As your product evolves, custom manufacturers can adjust specs step by step without starting over. This flexibility helps when:
Requirements change: custom designs can sometimes be tweaked using the same materials to meet new requirements.
Markets demand higher efficiency or smaller sizes: With a custom collaborator, there may be opportunity for design changes that do not affect the entire assembly.
New technologies create chances for performance improvements within the same package size
With standard components, these changes often mean starting from scratch. Custom magnetic solutions let you build on what you've already done, saving your engineering work across product generations.
MRI machines, surgical tools, and diagnostic imaging equipment require quality components to function reliably.
In medical devices, reliability isn't just about convenience—it can be life or death. Custom transformers provide the stable, clean power that sensitive medical equipment needs, with backup features built specifically for healthcare settings.
The aerospace industry faces tough weight and space limitations that require compact, high-efficiency transformers. Components must also work in extreme temperatures, vibration, and radiation.
In aerospace, lighter and more efficient parts mean less fuel used and longer missions. Custom magnetics can meet the strict quality standards that aerospace and defense require.
Wind turbines and solar panels need high-efficiency inductors and transformers to handle changing power loads. The unpredictable nature of renewable energy creates unique challenges that standard parts struggle with.
Custom magnetic solutions improve power conversion and energy storage. In renewable energy, even small efficiency gains can greatly impact whether a project makes financial sense over its 20–30-year life.
Motors, sensors, and controllers in factories need precise power regulation. Custom magnetics provide the reliability needed in noisy and tough factory settings.
The harsh conditions of 24/7 manufacturing push components to their limits. Custom magnetics designed for these demanding environments help production lines avoid costly downtime while making equipment last longer.
EVs need high-efficiency power electronics to maximize battery life and range. Custom transformers and inductors improve both charging systems and onboard power conversion.
Even small improvements in power conversion efficiency lead to better driving range and faster charging—key factors in EV buyer satisfaction. As EV technology changes rapidly, custom magnetic components can be updated to support new battery technologies and charging standards.
Think of custom magnetic components as an investment in your product's performance and lifespan, not just an expense. Here's why common concerns shouldn't hold you back:
Initial Cost vs. Total Value: While custom components may cost more upfront, they eliminate the need for workarounds and additional parts. This can actually reduce overall system costs when considering simplified assembly, streamlined testing, and improved reliability in the field.
Production Timeline: Modern custom manufacturers have streamlined their processes to compete with off-the-shelf timing. Many offer rapid prototyping that helps prevent costly redesign cycles and delays. With the right partner, custom magnetic components can often be delivered quickly enough to keep your project on schedule.
Design Process: Clear specs and teamwork make customization straightforward. Most engineers find that the time spent defining requirements saves trouble later by avoiding the problems that come from forcing standard parts to fit non-standard uses. Starting with a thorough design discussion helps identify potential issues before they become costly problems.
Minimum Order Quantities: Worried about being forced to order large quantities? Many custom manufacturers now offer flexible production options. They understand that new products often start with smaller production runs before scaling up and will work with you to find the right balance of cost efficiency and order size.
Choosing between standard and custom components isn't just about cost. It's about making products that perform their best in tough markets.
Custom magnetic components offer form, function, and benefits that prevent hidden costs and reliability problems. This is why industry leaders in medical technology, aerospace, renewable energy, and industrial automation use custom solutions to gain an edge.
Working with expert engineers ensures the best design choices for your specific needs. In today's challenging manufacturing world, these advantages can make the difference between a product that just works and one that truly stands out.
Ready to give your product an edge? Contact us today for help with your specific application. Our team of experienced engineers will help you find the perfect magnetic solution for your next product innovation.
Your equipment is down. The transformer failed—and replacements haven’t existed for years. Every day offline costs thousands. Without that magnetic component, the entire system stalls. This scenario plays out in factories, military installations, and medical facilities every day.
Legacy equipment often remains functional and valuable long after manufacturers discontinue support. When magnetic components fail in these systems, operators face difficult choices: expensive equipment replacement, risky third-party alternatives, or complete system retirement.
For effective legacy equipment repair, reverse engineering magnetics offers another path—recreating essential transformer components even when original documentation no longer exists. By carefully analyzing failed components, specialists can develop replacement parts that match or even improve upon original specifications—extending equipment life and avoiding costly system replacements.
Reverse engineering magnetics means disassembling failed transformers or inductors to uncover their exact design and performance. Like solving a puzzle with missing pieces, engineers must decode not just what it did—but how.
The process typically includes:
Physical examination of the damaged component
Careful disassembly (often destroying the original)
Documentation of winding patterns, wire sizes, and core materials
Electrical testing to determine key parameters
Recreation of design specifications
Prototype development and testing
Production of replacement components
For equipment manufacturers and maintenance teams, this process can salvage mission-critical systems when original parts are no longer available. It's particularly valuable in industrial, aerospace, medical, and military applications where equipment lifecycles often exceed component availability.
Legacy systems in aerospace, defense, and medical industries were built to last—but their magnetics weren’t. As components degrade, support disappears, and OEM replacements become impossible to find, creating what McKinsey & Company calls a growing “obsolescence challenge” for OEMs in industrial and defense sectors.
Finding exact replacements becomes nearly impossible. This creates serious problems, especially in highly regulated industries where swapping parts isn't just about function—it's about compliance. Medical devices, defense systems, and aerospace equipment all require strict validation for any component changes. Even when a similar transformer might electrically work, it could violate certification requirements or safety standards.
When critical infrastructure relies on legacy equipment, the cost of total system replacement often far exceeds the cost of reverse engineering a single component. In many cases, reverse engineering can save tens or even hundreds of thousands of dollars while getting systems back online in days rather than weeks or months.
Not every situation calls for reverse engineering. Sometimes, standard replacements or complete system upgrades are more practical. Reverse engineering typically makes the most sense when:
The equipment holds significant operational or financial value
Replacement systems would require extensive redesign, recertification, or retraining
Compliance-sensitive industries (AS9100, ISO9001, medical) need exact replacements
Downtime costs are extremely high
Original manufacturers no longer support the equipment
The unique magnetics are no longer manufactured
But there are limitations. Very complex designs with proprietary materials or specialized components may be difficult or impossible to reproduce. And without certain key information, engineers might need to make educated guesses about some specifications.
In December 2017, an electronic repair firm approached Electronic Craftsmen with a challenge. They had multiple GE power supplies failing due to problematic transformers. With no design documentation available and more units failing daily, they needed a solution fast.
The customer provided epoxy-sealed transformer samples, traced circuit board layouts, and created a sketched schematic. They also took inductance measurements and captured oscilloscope traces. From this limited information, our team identified the component as a "Gate Drive Transformer"—a device that couples gate-drive circuits to MOSFETs and IGBTs, modifies voltage levels, matches impedance, and provides isolation.
Space constraints on the circuit board made the replacement design challenging. To understand the internal construction, we dissolved the epoxy encasing the failed transformer. This revealed critical details about wire size and turn ratio. Based on the exposed physical characteristics and electrical parameters, we developed an entirely new design.
The original used a toroidal core, but our redesign employed an EFD20 platform using 3F3 core material. The gate side utilized triple-insulated TEX-E magnet wire. Drawing on our experience, we determined that expensive epoxy molding wasn't necessary—a simple air-dry varnish would suffice, reducing costs.
After confirming fit, the customer ordered 10 prototypes. We shipped them within a week. By late February, the transformers were field-tested and approved—followed by a 50-unit reorder. The entire project—from problem identification to field-tested solution—took just two months. Read the full GE power supply case study.
Reproducing magnetic components isn't always straightforward. Engineers commonly face these obstacles:
Without original design documents, engineers have to work backward from a failed component. It’s like trying to rebuild a custom tool just by looking at a broken one—you can measure the obvious dimensions, but the exact materials, internal layering, or subtle design choices aren’t always visible. And sometimes, those are the details that matter most.
Varnishes, insulation methods, and winding techniques all impact performance but may not be immediately obvious. An experienced engineer must make informed decisions about these details based on application requirements and physical evidence.
Core materials significantly impact transformer performance. Ferrite compositions, silicon steel grades, and specialized alloys each have unique electromagnetic properties. Identifying the exact material in a decades-old component can be nearly impossible.
Today's material options often differ from those available when legacy equipment was manufactured. Engineers must select modern equivalents that provide similar or better performance characteristics without altering the component's function in the system.
Legacy equipment wasn't designed with replacement in mind. Space limitations, unusual mounting methods, and unique connection types all restrict redesign options. The replacement must fit exactly where the original did—both physically and electrically.
In aerospace applications, this challenge often intensifies. Reverse-engineered components must meet strict physical and functional criteria—including dimensions, mounting methods, and sometimes weight distribution—to maintain compliance and performance. This article explains why these factors are critical when duplicating flight-certified components.
Reverse engineering isn't just about creating exact copies. It offers opportunities to improve on original designs using modern materials and techniques:
Legacy transformers often fail due to heat. Modern insulation and winding techniques improve thermal management—delivering better heat dissipation while preserving original specs and footprint.
Original equipment often used materials and techniques that have been surpassed by modern alternatives. Triple-insulated wire, advanced core materials, and better varnishes can extend component lifespan significantly. This makes reverse-engineered replacements potentially more reliable than the originals they replace.
Original designs sometimes used expensive manufacturing methods that are no longer necessary. In the GE power supply case study, switching from epoxy molding to air-dry varnish reduced costs without compromising performance.
But some changes risk altering component behavior in unpredictable ways. Engineers must carefully balance potential improvements against the need for functional equivalence. This requires both technical expertise and practical experience with legacy systems.
When facing legacy equipment failures, consider these factors before choosing reverse engineering:
System Value: Does the equipment's operational or financial value justify custom component development?
Urgency: Can you tolerate extended downtime while replacements are developed?
Complexity: Are the failed components suitable for reproduction?
Documentation: What information is available about the original design?
Quantity Needed: Will you need multiple replacements now or in the future?
Reverse engineering might cost more than off-the-shelf components initially, but when evaluated as part of a comprehensive legacy equipment repair strategy, it often proves more economical than complete system replacement. It's particularly valuable when you need multiple replacements over time or when a single component failure would sideline expensive equipment.
Reverse engineering magnetics requires specialized knowledge, testing capabilities, and manufacturing expertise. Electronic Craftsmen brings over 60 years of custom magnetics and power electronics experience to each reverse engineering project.
With AS9100 and ISO9001 certifications, Electronic Craftsmen meet the stringent quality standards required by aerospace, defense, and medical industries. This matters when recreating components for critical systems where failure isn't an option.
The company maintains in-house tooling, material sourcing, and comprehensive testing capabilities—essential for accurately reproducing legacy components. Their experience spans aerospace, defense, industrial, and telecommunications applications, providing the knowledge base needed to tackle diverse magnetic designs.
This expertise means they're not just making parts—they're replicating performance-critical solutions that must function exactly like the originals in complex systems.
Magnetic components are often the weakest link in otherwise reliable legacy systems. When these custom parts fail, entire production lines, labs, or communication systems can come to a standstill. But reverse engineering can bring them back to life.
Advances in materials and design now make it possible to recreate magnetic components that match—or even improve on—original specs. With the right expertise, decades-old equipment can keep running efficiently.
A failed transformer doesn’t have to mean system retirement. Contact us before replacing valuable legacy equipment. Even without documentation, their engineers can often develop a working solution that restores full functionality.
You don’t have to choose between full system replacement and costly downtime. Many legacy systems still have years of performance left—with the right magnetic solutions behind them. Why not explore an option that could save time, money, and extend the life of your most trusted equipment?
One of the most critical components when designing a power supply for your equipment is a compatible transformer. If your equipment doesn’t receive the correct voltage, things can go downhill fast. Overheating components and equipment malfunctions are disasters waiting to happen. In industries that depend on precision—like medical, aerospace, and manufacturing—small power fluctuations can lead to costly downtime and failures.
A transformer does more than adjust voltage—it protects equipment, improves efficiency, and ensures reliability. Choosing the right one minimizes downtime, extends equipment life, and controls costs.
At its core, a transformer is just coils of wire wrapped around an Iron or ferrite core. Voltage is applied to one coil (the primary winding), creating a fluctuating magnetic field. That fluctuating field then transfers energy to the second coil (the secondary winding), “transforming” the applied voltage.
If the secondary coil has more windings than the primary winding, the voltage increases (step-up transformer). If it has fewer, the voltage decreases (step-down transformer). The frequency stays the same, but the transformer designer can vary the primary to secondary turns ratio to match what the system needs.
You’ll find transformers everywhere, keeping power stable and reliable:
Aerospace & Aviation – Powering radar, flight controls, and navigation systems.
Medical Equipment – Delivering stable voltage to MRI machines, surgical tools, and lab equipment.
Manufacturing & Automation – Preventing voltage fluctuations that could shut down assembly lines.
Renewable Energy – Converting power from wind and solar into usable electricity.
Different industries have very specific power needs. The wrong transformer can lead to wasted energy, equipment failures, or expensive downtime. The right one ensures efficiency, reliability, and long-term performance – which is why picking the right transformer isn’t just a technical decision. It’s a business-critical one.
A transformer is what keeps power stable and equipment running the way it should. But if the transformer isn’t a good match for the system, the consequences go beyond inefficiency. Poor voltage control leads to wasted energy, unstable performance, and in some cases, complete system failure.
When a transformer isn’t designed for the load it’s handling, energy gets lost as excess heat instead of useful power. That heat buildup isn’t just wasteful – it puts extra stress on the system. In industrial settings, even small inefficiencies add up. A factory running multiple misaligned transformers could be losing thousands of dollars in wasted electricity every year.
Unstable power is a slow killer. When voltage keeps shifting up and down, sensitive electronics start to wear out. Medical imaging machines, for example, require less than a 1% variation in voltage to function properly.
A transformer that can’t maintain steady output could cause distorted scans or unreliable test results. In manufacturing, unstable voltage can shut down automated systems or throw off precision equipment, leading to defects and downtime.
A transformer that isn’t rated for the job runs hot. And when it overheats, the entire system is in danger. Over time, excessive heat weakens insulation, damages wiring, and increases the chances of short circuits. In extreme cases, it can lead to catastrophic failures that take down an entire operation.
A large solar energy facility saw 30 transformer failures in six months. The cause? The transformers weren’t designed for the plant’s specific load requirements. The insulation inside them broke down under high temperatures, leading to repeated shutdowns. After switching to properly rated transformers, the failures stopped, and power output stabilized. Read the full case study here.
A well-designed transformer protects the system just as well as it powers it. In industries like healthcare, aerospace, and manufacturing, unreliable power isn’t just inconvenient – it’s a financial and operational risk. Choosing the right transformer ensures:
Consistent power flow to keep operations running without interruptions.
Lower maintenance costs by preventing overheating and equipment wear.
Longer lifespan for both the transformer and the equipment it powers.
The bottom line? A transformer might seem like a small part of a larger system, but when it’s the wrong one, the costs go far beyond just replacing a faulty component.
Not all transformers are created equal. While standard, off-shelf models work in some cases, many industries require precision power control that generic transformers can't provide. That's where custom transformers come in. They're designed to match specific voltage, current, and environmental demands, ensuring that equipment runs efficiently and safely.
Every system has unique power needs. Some equipment demands exact voltage with zero fluctuation, while others handle high loads and need specialized insulation to prevent overheating. A custom transformer matches these exact specifications, avoiding the risks of one-size-fits-all solutions.
In medical technology, aerospace, and automation, space matters. Standard transformers often prove too bulky or inefficient for tight spaces. Custom transformers fit specific size and weight limits without compromising power delivery.
Some environments push equipment to its limits. Systems might face extreme temperatures, constant vibration, or corrosive conditions where standard transformers fail. Custom-built units handle:
High heat and humidity in mining operations
Constant vibration in aerospace applications
Outdoor exposure in renewable energy system
Healthcare, aviation, and defense have strict regulations. Equipment must meet specific safety and performance standards. Custom transformers comply with these certifications from the start, preventing compliance issues and expensive fixes later.
A transformer isn't just another electrical component – it's the backbone of your power system. It regulates voltage, ensures equipment operates efficiently, and protects against costly failures. When chosen correctly, a transformer keeps power stable, extends equipment life, and reduces energy waste. But the wrong transformer leads to overheating, equipment malfunctions, and unplanned downtime – problems that cost thousands in repairs and lost productivity.
Transformer failures don't just stop one machine – they shut down entire operations. Manufacturing lines freeze, costing thousands per hour in lost production. Data centers crash, affecting countless users and damaging client trust. Hospitals face delayed procedures and compromised patient care. A properly matched transformer prevents these issues by maintaining reliable, stable power.
Poor transformer efficiency wastes power as heat, driving up electricity bills and straining cooling systems. In industrial settings, even small efficiency improvements save thousands annually. Better transformers minimize losses through improved design and materials, turning more input power into usable output instead of waste heat.
Power fluctuations kill equipment fast. High voltage burns out electronics. Low or unstable voltage makes systems work harder, wearing them out sooner. Motors fail early, circuit boards break down, and precision machines lose calibration. Quality transformers prevent these issues by delivering exact voltage levels without fluctuation.
Many industries face strict power regulations. Medical facilities need specific power quality for patient safety. Aerospace requires transformers that meet rigorous standards. Using the wrong transformer means failed inspections, regulatory violations, and expensive fixes.
While cheaper transformers save money upfront, long-term costs add up through frequent repairs, higher energy bills, damaged equipment, and production losses. For industries where power quality affects performance and safety, the right transformer is essential for operational success.
At Electronic Craftsmen, we specialize in transformers that match your exact needs. Our team works with you to understand your requirements, space limitations, and operating conditions. We'll help design a solution that keeps your systems running reliably for years to come.
Ready to improve your power system? Let's talk about how we can help make your equipment work better, last longer, and cost less to operate.
When you’re pricing your next custom transformer or inductor, it’s critical to get the specifications right, the first time. Our products and your applications demand precision…usually that involves some back-and-forth with engineers to gather all the information needed to generate an accurate quotation.
E Craftsmen offers a wide range of custom magnetics, each one with its own unique specification, so we created this one-page guide to use as a checklist to help you scope out all the details.
Our Quick Specifications Guide for Custom Magnetics will help you ensure that you’ve acquired all the pertinent details from electrical specifications to physical constraints and regulatory needs. Download the guide here and keep it handy to take along to your next design review meeting. We hope it’s a big help!
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Designed primarily for Step-Down power supply for LED lighting devices, these products are Certified to both the U.S. and Canadian standards for General Purpose Component Transformers. |
The benefit to our customers is that the widely-recognized UL approval will simplify the acceptance of these compact transformers within their end-use fixtures by most safety certification organizations.
Because these parts are approved with this additional rating, they can be used in equipment with higher ambient temperatures.
With their low-profile height of only 1.31 inches and narrow width of 1.63 inches, these transformers are sure to fit the small-size requirements of today's LED fixtures.
We have custom transformers to meet your needs, plus we don't charge for quotes and designs, contact us!
Manufacturing is making a comeback in North America. But downward pressure persists from offshore commodity suppliers so time & cost-saving is the nature of the game.
R&D for new products with improved features, in smaller packages in increasingly shorter time frames is, for many, the only answer to declining revenues.
Why choose custom-made versus standard parts?
Logically, the first step for a designer to control material costs is to source standard, off-the-shelf components. The belief is that settling for a standard part will provide initial cost-savings vs. the superior choice of a custom-made part that will better suit the application. While this may be the case from a basic purchasing perspective, there are a number of design issues that may challenge that "price-only" choice over the long-term. (Not to mention that "catalogue" parts are rarely "on-the-shelf" anymore.)
Form and Fit: A Custom part expertly designed with consideration to dimensions, physical constraints and terminations will likely yield a much more effective solution rather than simply “settling” for a standard part that doesn't really fit. Unexpected time needed to rework a packaging layout can result in excessive design-cycle costs. Experienced magnetic designers have exposure to a wide range of materials and innovative methods to develop a part tailored to fit just right.
Function: Losses in a transformer or inductor due to ripple currents and harmonic content can cause unexpected over-heating. Weeks lost in waiting for delivery of a low-cost catalogue part followed by set-backs due to inadequate or even dangerous performance can put the development cycle of a new product into jeopardy.
Duty cycle: Expert attention given to intermittent operation duty cycle in a custom design generally results in a dramatically smaller, cooler and cost-effective part than originally estimated.
Expert Collaboration: Often, doing it yourself takes more time and leads to frustration. Working with a professional that is skillfully trained in the design of magnetics can offer invaluable insights and know-how that are just not available from that “order-taker” at the electrical distributor.
All in all, what appears to be short-term gain can result in long-term pain when it comes to procuring parts best suited to the application. Don’t just “settle”… Send us your specs and we'll give you a qualified quote! on a better design.
In response to a market need, E Craftsmen has developed a family of agency approved 347V Step-Down Autotransformers. This voltage is unique to Canadian commercial and industrial installations and represents the line-to-neutral phase of the standard 600V 3-phase power grid. Most of these requests come from the lighting industry and relate to the increasing popularity of LED lighting.
Typical world-wide primary voltage is in the range of 100 to 240V at 50 or 60Hz. As a result, a number of power-supply manufacturers have developed off-the-shelf devices that will accept any voltage between 100-240V (known as ‘universal input supplies”). This approach is adequate in many installations but typically in commercial and industrial sites, lighting is powered by 347V and these universal input power supplies are not capable of operating at this higher voltage.
Consequently, the installation requires that the 347V be converted or “stepped-down” to 220-240V in order to be connected to these power supplies. The most cost-effective method of stepping down from 347V is by use of an autotransformer. Most importantly, the autotransformer must be designed in such a way as to satisfy safety requirements for 347V input.
Power ratings include 50VA, 100VA and 240VA with efficiencies of 93% and up. The unique “Low Profile” form factor of these parts is ideal for fluorescent ballast retrofit and numerous other similar applications. Of course, there are numerous other ratings and sizes available that can be customized to specification…contact us for details!
More Information about the 347V
Star Trek would have us instantly teleporting across distance & space but until that becomes a reality, we must rely on planes, trains & automobiles (and occasionally boats) to get materials from suppliers to customers.
With over 60 years of experience in supplying our custom parts to customers throughout North America and across the oceans, we've encountered our share of "unfortunate events" with shipping. So here are a few things to think about in the pursuit of getting your parts on time, intact, and at a somewhat reasonable cost.
OK, so we’ve been a little hard on some of the big carriers but please know that we use many of them daily because they generally get the job done...and we know the ups & downs. The main point is that with just a little preparation in advance, we’ll get your parts to you safe & sound, on-time and at a cost that won’t empty your wallet.
