Power Supply Design Services
Custom AC-DC / DC-DC power supply design โ From milliwatt IoT regulators to multi-kilowatt industrial converters. High efficiency, low EMI, field-proven reliability.
Power Supply Design Expertise
AC-DC Converters
Flyback, forward, LLC resonant, and PFC topologies from 5 W to 3 kW. 85-265 VAC universal input with active power factor correction (IEC 61000-3-2).
DC-DC Converters
Buck, boost, buck-boost, SEPIC, and isolated flyback/push-pull designs. Wide input range (4.5-60 VDC), synchronized rectification, and multi-rail sequencing.
EMI Compliance
Pre-compliance scanning and mitigation: conducted/radiated EMI filter design, snubber optimization, spread-spectrum modulation, and shielding techniques per CISPR 22/32.
Thermal Management
Thermal simulation, heatsink optimization, PCB copper pour design, and fanless convection cooling strategies for sealed enclosures operating in -40ยฐC to +85ยฐC ambient.
Power Supply Design Process
Power supply design is one of the most unforgiving disciplines in electronics engineering. A subtle oversight in magnetics design, feedback loop compensation, or PCB layout can cascade into field failures, EMI certification rejections, or thermal runaway. At InnovChip, we approach every power supply design with a rigorous, simulation-backed methodology that has been validated across dozens of production deployments in industrial, medical, and IoT applications. Our process begins with a thorough specification analysis: input voltage range (AC mains or DC battery), output rails (voltage, current, ripple, regulation, transient response), efficiency targets, isolation requirements, and environmental conditions.
With the specification locked, we move to topology selection and component sizing. For low-power designs under 30 W, we typically select flyback or buck topologies for their simplicity and low BOM count. For mid-power (30-150 W), we evaluate forward, active-clamp forward, and quasi-resonant flyback topologies. Above 150 W, we transition to LLC resonant converters for their zero-voltage switching (ZVS) advantages, or interleaved PFC + isolated DC-DC stages for universal-input designs requiring EN 61000-3-2 harmonic compliance. Transformers and inductors are designed in-house using the Area Product (Ap) method, with core material selection (ferrite, powder iron, amorphous) driven by frequency, flux density, and loss budgets. Windings are optimized for low AC resistance through interleaving and Litz wire where applicable.
Feedback loop compensation is where many designs go wrong. We perform analytical Bode plot analysis (using Mathcad/Python) to ensure adequate phase margin (>45ยฐ) and gain margin (>10 dB) across all operating conditions โ minimum and maximum input voltage, no load to full load, and across temperature. For digital power supplies (where an MCU closes the control loop), we implement PID or 2-pole/2-zero compensators with anti-windup and feed-forward terms, running at PWM frequencies from 100 kHz to 1 MHz depending on the power stage and switching device capabilities.
Wide Bandgap and Advanced Technologies
The power electronics industry is undergoing a fundamental shift from silicon MOSFETs and IGBTs to wide bandgap (WBG) semiconductors โ GaN (Gallium Nitride) and SiC (Silicon Carbide). We actively design with both technologies. GaN HEMTs enable switching frequencies above 1 MHz with dramatically reduced gate charge (Qg) and output capacitance (Coss), allowing smaller magnetics and higher power density. We have designed GaN-based converters achieving >95% efficiency in a 65 W USB-PD adapter form factor. SiC MOSFETs and diodes excel in high-voltage applications (>600 V) with near-zero reverse recovery charge, making them ideal for PFC stages, solar inverters, and EV on-board chargers.
For battery-powered and energy-harvesting systems, we design ultra-low quiescent current power supplies using nanoPower buck/boost converters (sub-300 nA Iq) with dynamic voltage scaling and load-disconnect features. These designs are critical for IoT sensor nodes that must operate for 5-10 years on a single primary lithium cell.
Safety and Certification Support
Safety is non-negotiable in power supply design. We design to IEC 62368-1 (audio/video/IT), IEC 60601-1 (medical), and IEC 61010-1 (measurement/control) safety standards as required by your target market. This includes creepage and clearance calculations per IEC 60664, fuse selection and protection coordination, over-voltage category (OVC) classification, and protective earth bonding. We provide a complete certification support package โ schematic markup with safety-critical components identified, PCB layout with isolation barrier measurement callouts, transformer construction drawings with triple-insulated wire specifications, and a compliance checklist mapped to each clause of the applicable standard.
Technologies We Master
LLC Resonant
Buck / Boost / SEPIC
Active PFC
GaN HEMT
SiC MOSFET
Magnetics Design
Loop Compensation
EMI Filtering
IEC 62368-1
IEC 60601-1
CISPR 22/32
USB-PD (3.1 EPR)
Thermal Simulation
Need a Custom Power Supply?
Share your input/output specs โ we deliver a complete design with schematic, BOM, magnetics, and PCB layout ready for prototyping.