Magnetic Design in Modern Power Electronics

Magnetics remain one of the most critical — and most challenging — aspects of power electronics design. As switching frequencies increase and power densities rise, the design of transformers, inductors, and coupled magnetics requires ever more sophisticated analysis and simulation. Our product development team specializes in custom magnetic component design for power converters operating at frequencies from 50 kHz to several MHz. Using advanced FEA tools like COMSOL and ANSYS Maxwell, we optimize core geometry, winding configurations, and thermal management to achieve maximum efficiency in minimal footprint. Recent projects have included planar transformers for 3.3 kW onboard chargers, high-frequency inductors for solar inverters, and custom current sensing transformers for BMS applications. Each design presents unique trade-offs between core losses, copper losses, EMI, and thermal performance. The move toward wide-bandgap semiconductors (SiC and GaN) is pushing magnetic design to new frontiers, enabling switching frequencies above 1 MHz where traditional design rules no longer apply. Engineers who understand both the physics and the practical manufacturing constraints are in high demand.