Custom switching power supply (SPS) services cater to applications with unique requirements that standard off-the-shelf models cannot meet, such as specific form factors, extreme environmental conditions, or non-standard input/output parameters. These services follow a structured process to deliver tailored solutions while ensuring compliance with industry standards.

The first phase involves detailed requirement analysis. Engineers work closely with clients to define key parameters: input voltage range (e.g., 9–36 V DC for industrial use, 85–265 V AC for universal mains), output specifications (voltage, current, ripple, regulation), environmental constraints (temperature range, humidity, vibration, radiation), form factor (e.g., PCB-mounted, enclosed, rack-mounted), and safety/certification needs (UL, CE, medical EN 60601). This phase also includes identifying critical performance goals, such as high efficiency (>95% for battery-powered devices) or low noise (<10 mV ripple for audio equipment).

The second phase focuses on design and prototyping. Using specialized software (e.g., PSpice for circuit simulation, SolidWorks for mechanical design), engineers develop a custom circuit topology (e.g., buck-boost for wide input ranges, LLC resonant for high efficiency) and select components optimized for the application (e.g., rad-hard components for aerospace, high-temperature capacitors for automotive). A prototype is then manufactured to validate performance: tests include efficiency measurement, thermal analysis (using infrared imaging), EMI testing (per CISPR 22), and environmental stress testing (temperature cycling, vibration). Iterations are made based on test results to refine the design.

The third phase involves production and certification. Once the prototype is approved, the custom SPS enters mass production, with strict quality control checks (e.g., component inspection, functional testing) at each stage. Engineers also assist with certification testing to meet client-specific standards (e.g., IEC 61010 for test equipment, DO-160 for avionics). Post-production support includes technical documentation (schematics, user manuals), troubleshooting assistance, and optional warranty extensions (e.g., 3–5 years for industrial applications).

Key benefits of custom SPS services include optimized performance (tailored to specific load conditions), space efficiency (compact designs for constrained environments), and long-term reliability (components selected for the application’s lifecycle). However, they require longer lead times (8–16 weeks vs. off-the-shelf) and higher upfront costs, making them most suitable for applications where standard models fail to meet critical requirements (e.g., aerospace, medical devices, industrial automation).

Read recommendations:

LED Power Supply 150W

PD multi-port wall plug 2A2C

20V2A Wall Plug Australian Standard

12V medical power supply for home use

Compact 500W Battery Charger for Space-Saving