Custom Ferrite Transformers For SMPS: When Off-the-Shelf Isn’t Enough

How Shinhom Solves Your Critical Power Challenges
Thermal imaging shows our custom transformer runs 15°C cooler than standard units (tested at 25℃ ambient)

That "Almost Perfect" Off-the-Shelf Transformer? Why It Fails

Last month, a medical device maker recalled 10,000 units because their SMPS transformers caused electromagnetic interference (EMI) in MRI rooms. Their "standard" ferrite core? Almost met requirements... but "almost" costs $2M in recalls.

You've seen the symptoms:

🚫 Size mismatches forcing PCB redesigns

🔥 Unexpected overheating at high frequencies

📉 Efficiency drops under real-world loads

Industry data reveals 68% of engineers face these issues with catalog transformers (Source: Power Electronics News Survey, 2023).

Why Custom Becomes Critical

1. Frequency Flexibility

Standard ferrite cores typically operate at 50-100kHz. But modern SMPS designs push to 2MHz+. Our patent-pending laminated cores reduce eddy currents by 40% at high frequencies (Shinhom Lab Test Report #TF211).

2. Thermal Optimization

When a leading EV charger maker struggled with 125℃ hotspots, we redesigned the core with:

Copper-embedded heat sinks

Vacuum pressure impregnation (VPI)
Result: ΔT reduced from 42℃ to 23℃ under 10kW load.

3. Extreme Environment Protection

Standard transformers fail salt-spray tests in 24 hours. Our MIL-grade nano-crystalline coating passes 96-hour salt fog tests (ASTM B117 certified).

https://www.shinhom.com/images/custom-vs-standard-chart-en.png
Performance data from Shinhom internal benchmarking (2024)

Your Customization Roadmap

Our 4-step process ensures precision:

Requirements Capture
→ Complete our Interactive Spec Sheet

3D Simulation
Electromagnetic & thermal modeling (ANSYS-certified)

48-Hour Prototyping
Real samples – not just CAD drawings

Lifecycle Support
Including core recycling for cost recovery

Real-World Wins