Initial Situation
A certain company from the industrial automation sector approached TPS Elektronik with the need to modernize a specialized power controller used in high-demand production environments. The device required effective thermal management, which meant developing a new CNC-machined heat sink.
The existing product had been supplied by another vendor more than 20 years ago. However, the previous contract manufacturer could no longer continue production due to economic and technical limitations. The challenge was to completely redesign the outdated device while ensuring compliance with CE standards.
Key obstacles included:
- Only one old sample device was available – no technical documentation existed.
- The original unit did not pass EMC testing and therefore failed CE requirements.
- A new cooling system was needed, requiring precision China CNC machining of a complex heat sink.
- Production had to be scalable, starting with small batch production and later moving toward higher volumes.
TPS Elektronik’s Solution
As an experienced manufacture and manufacturer, TPS Elektronik combined rapid prototyping China with advanced contract manufacturing collaboration to deliver a modernized, fully compliant solution.
We implemented the following measures:
- Electronic redesign – A new circuit and optimized PCB layout were developed, significantly improving EMC performance to ensure CE approval.
- User interface upgrade – We added modern control interfaces and an integrated display for easier operation.
- New housing and cooling – The heat sink was manufactured using high-precision China CNC machining, ensuring improved thermal conductivity, stable operation, and higher IP protection.
- Flexible manufacturing – By starting with small batch production, we allowed the customer to test and validate the new regulator before scaling up. Our role as both contract manufacturer and original design manufacturer (ODM) ensured smooth transition from prototype to production.
Results
The collaboration between TPS Elektronik and the customer led to measurable success:
- CE compliance achieved: The redesigned device passed EMC testing without issues.
- Improved cooling efficiency: The CNC-machined heat sink increased thermal performance by over 30%.
- Market validation: Thanks to small batch manufacturers support, the customer was able to reintroduce the product quickly.
- Long-term partnership: Ongoing contract manufacture collaboration ensures continued supply and design updates.
Conclusion
This project highlights how TPS Elektronik delivers added value as both a contract manufacturer and original design manufacturer. By combining rapid prototyping China, small batch production, and precision China CNC machining, we transformed a legacy product into a modern, CE-approved solution.
Through reliable contract manufacturing collaboration, TPS Elektronik helps customers achieve product modernization, regulatory compliance, and long-term production security.
