Initial Situation
A company from the industrial automation sector approached TPS Elektronik with the need to modernize a specialized power controller used in demanding production environments. Effective thermal management was essential, requiring the development of a new CNC-machined heat sink.
The original product had been supplied by another vendor more than 20 years ago. Since the previous contract manufacturer could no longer continue production due to economic and technical limitations, the device had to be completely redesigned while ensuring compliance with CE standards.
Key challenges included:
-
Only a single sample unit was available, with no technical documentation.
-
The original device had failed EMC testing and therefore did not meet CE requirements.
-
A new cooling system was required, involving precision CNC machining of a complex heat sink.
-
Production needed to be scalable, starting with small batches and later ramping up to higher volumes.
TPS Elektronik’s Solution
As an experienced manufacturing partner, TPS Elektronik combined rapid prototyping with advanced contract manufacturing to deliver a modernized and fully compliant solution.
Implemented measures included:
-
Electronic redesign: A new circuit and optimized PCB layout significantly improved EMC performance to enable CE certification.
-
User interface upgrade: Modern control interfaces and an integrated display were added for easier operation.
-
New housing and cooling: A CNC-machined heat sink provided improved thermal conductivity, stable operation, and enhanced IP protection.
-
Flexible manufacturing: Beginning with small-batch production allowed the customer to test and validate the new regulator before scaling. TPS’s role as both contract manufacturer and Original Design Manufacturer (ODM) ensured a smooth transition from prototype to series production.
Results
The collaboration between TPS Elektronik and the customer delivered clear, measurable outcomes:
-
CE compliance: The redesigned device successfully passed EMC testing.
-
Improved cooling performance: The CNC-machined heat sink increased thermal efficiency by approximately 30%.
-
Market re-entry: Small-batch production enabled a rapid return of the product to the market.
-
Long-term partnership: Ongoing cooperation in contract manufacturing secures continued supply and design updates.
Conclusion
This project demonstrates how TPS Elektronik creates value as both a contract manufacturer and an Original Design Manufacturer (ODM). By combining rapid prototyping, small-batch production, and precision CNC machining, TPS transformed an outdated product into a modern, CE-certified solution.
Through reliable cooperation in contract manufacturing, TPS Elektronik supports its customers in achieving product modernization, regulatory compliance, and long-term production security.
