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Custom Designed Magnetics

Custom Designed Magnetics

MPS Industries provides reliable custom magnetic designs that meet specific application requirements in industries including automotive, aerospace, medical, and telecommunications.

We are an industry-leading manufacturer of custom magnetic components like custom inductors, chokes, current sensors, and custom transformers. Learn more about our capabilities and our manufacturing process, along with some design considerations for custom magnetic components.

Why Customized Magnetic Components Matter

Magnetic components can be one of the largest, heaviest, and most expensive components on a system’s board. Optimizing these components for performance within a specific application often helps reduce overall system size, weight, and cost.

Custom magnetic solutions give you the functionality that’s needed without making adjustments or compromises associated with using a “close enough” off-the-shelf option. Some advantages include:

Adaptability

Adaptability

Custom designs can be modified as an application’s specifications, market demands, or performance goals change, without starting the design over from scratch or selecting a new stock component.

Improved Efficiency

Improved Efficiency

Coils can be engineered to integrate seamlessly into a system. They can also be designed with custom connection points to make the assembly process faster and easier.

Meets Exact Specifications

Meets Exact Specifications

Custom magnetic components can be developed to perform as required within the constraints of the system, instead of “shoehorning in” a stock component.

Precision Performance

Precision Performance

Custom inductors and transformers meet the precise frequency and volume requirements of the application. They can also match impedance, frequency response, and power transfer ratios.

Our Custom Magnetics Design Capabilities

At MPS Industries we develop and manufacture these types of custom magnetic products:

Chokes Chokes
Chokes Differential and common mode chokes protect signal integrity and suppress noise.
Current Sensors Current Sensors
Current Sensors These provide accurate control and monitoring.
Custom Inductors Custom Inductors
Custom Inductors Options include air coil, helical edge wound (HEW), laminated core, molded, power factor correction (PFC), precision, resonant, surface-mount technology (SMT), and toroidal inductors.
Custom Transformers Custom Transformers
Custom Transformers Audio, isolation, power, radio frequency (RF), telecom, and video transformers can be tailor-made to meet specific application requirements.
Our talented engineering team works closely with our customers to understand the application’s requirements and develop a solution that meets them.

The Magnetic Component Design Process | From Conception to Completion

Our custom magnetics design and manufacturing includes these steps:

Gaining a thorough understanding of the specific demands of an application, including the environmental, electrical, and mechanical parameters.

We assess bare component design and can provide estimations for loss and temperature rise. After customers validate electrical performance, our team can also develop mounting hardware for the application.

We test that all parts perform as expected, followed by the customer performing tests with their existing system to validate the design.

Once the design has been tested by our team and the customer, no further changes are made until the customer gives final approval. In some cases, we may also obtain no-change agreements that specify materials, processes, manufacturing locations, and other production details.

We take steps to maintain product consistency and quality while scaling up manufacturing.

Performance data and other feedback gathered during prototype testing and validation in step four determine how the project will proceed. It is very common for testing to reveal needed adjustments, errors, or manufacturing challenges. In these cases, our team will repeat steps one through four as needed until a satisfactory design is achieved. Only then do we move on to full production.

We bring years of experience to custom magnetic design and engineering, and we can work with you to achieve compliance certification for your application.

Industries We Serve

MPS Industries provides top-quality, dependable custom magnetic components for customers in many industries, including:

Aerospace & Military

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Aerospace & Military

Reverse engineering capabilities to create obsolete components when specified for some military applications.

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Automotive

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Automotive

A wide variety of components for standard and electric vehicles, advanced driver-assistance systems (ADAS), and charging systems.

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Industrial

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Industrial

Custom solutions for power management, control systems, and automation.

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Medical

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Medical

Magnetics for diagnostic devices, imaging equipment, patient monitoring systems, and surgical equipment.

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Telecommunications

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Telecommunications

Magnetics for communication systems, networking equipment, and signal processing.

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Common Applications for Custom Magnetics

Custom magnetic components play a key role in advanced electronics systems, including the following applications:

Current Sensing

Current Sensing

Sensors provide precise current measurements for control and monitoring purposes.

EMI Suppression

EMI Suppression

Filters and chokes mitigate electromagnetic interference (EMI) in sensitive electronics.

Energy Storage

Energy Storage

Custom inductors manage the flow and stability of power in an energy storage system.

Power Conversion

Power Conversion

Custom transformers and inductors effectively transfer energy in converters and power supplies.

Signal Isolation

Signal Isolation

These components maintain signal integrity and prevent interference in communication systems.

Transformer vs. Inductor Design Considerations

Custom inductors and transformers are both magnetic components with unique design considerations and distinct functions.

Custom Transformers

Custom Transformers

Transformers rely on electromagnetic induction to transfer electrical energy between circuits, often for voltage isolation or conversion purposes. They are designed to maximize coupling and typically require at least two windings.

Custom Inductors

Custom Inductors

Inductors usually only require a single winding and are used for things like:

  • Storing energy in a magnetic field.
  • Filtering signals.
  • Managing current flow in circuits.

A transformer ensures efficient energy transfer and minimizes losses. An inductor, on the other hand, manages thermal performance and core saturation, with an emphasis on energy storage capacity.

Magnetic Materials and Specifications

Material choice directly affects how custom inductors and transformers perform in a system. The most common magnetic materials used for these include:

Ferrite

Ferrite: This reliable material has low electrical conductivity and high magnetic permeability, making it a good choice for high-frequency applications.

Iron Powder

Iron Powder: Distributed air gaps in this material make it ideal for applications requiring low core losses and high energy storage.

Nanocrystalline

Nanocrystalline: This material offers low core losses and high saturation flux density, which is desirable for compact magnetic component designs that operate at high frequencies.

These materials have properties that influence the size, efficiency, and thermal performance of the finished magnetic components. It’s important to understand how different materials will behave within your application and the advantages and potential downsides of each.

Compliance, Testing, and Quality Assurance

We follow careful testing protocols to ensure custom magnetic products meet safety and compliance requirements. MPS Industries is ISO 9001-certified for quality management.

Custom Magnetics Design by MPS Industries

At MPS Industries, we design and manufacture custom magnetics components including chokes, transformers, inductors, and current sensors for the automotive, energy, medical, communications, and other OEM industries. Our experienced engineers and design team work with you to understand your application, then develop, refine, and manufacture custom components that meet your requirements.

Contact us to request a quote today to learn more about our capabilities and start your next design.