System integrators, panel builders, and procurement teams often face a critical bottleneck: finding the right power supply. Off-the-shelf units rarely meet the exact dimensional, thermal, or electrical requirements of specialized industrial or medical equipment. Conversely, a ground-up custom design can consume months of engineering time and incur massive Non-Recurring Engineering (NRE) costs, delaying market entry. TPS Elektronik bridges this gap. Our custom power supply design leverages a modular, platform-based approach. By utilizing pre-engineered, pre-tested topologies, we deliver a customizable power supply solution that perfectly matches your specifications while drastically reducing development time and certification risks. From bare-board PCB assembly to full mechatronic integration, we provide turnkey power solutions.
Request a consultation for your custom power supply project →
1. The dilemma: Off-the-shelf vs. full custom power supply design
When developing complex systems, engineers usually start by searching for a standard power supply. However, standard units often fall short. They might lack the necessary peak power capability for motor drives, fail to meet stringent medical leakage current standards, or simply not fit into the mechanical envelope of a compact device. Forcing a standard unit to work often requires external filtering, additional cooling, or compromised system performance.
The alternative is a full custom power supply design. While this guarantees exact specifications, it introduces significant risks. Developing a new power topology from scratch requires extensive EMC testing, safety certifications, and thermal validation. This can add 6 to 12 months to a project timeline.
To understand how we navigate these challenges, explore our core capabilities in custom power supply engineering.
2. The solution: Modular power supply design and platforms
TPS Elektronik accelerates development through modular power supply design. Instead of starting from a blank schematic, our engineers utilize a library of proven, pre-certified power platforms. This platform power supply design methodology allows us to create a modified standard power supply that behaves exactly like a custom unit but is delivered in a fraction of the time.
A configurable power supply design might involve taking a standard active PFC (Power Factor Correction) front-end and pairing it with customized DC-DC output stages. Whether you need multiple isolated outputs, specific voltage sequencing, or unique communication interfaces (like PMBus or CAN bus), our platform approach accommodates these needs rapidly. Because the core switching topologies are already validated for EMC and safety, the regulatory approval process for the final customized unit is significantly streamlined.
3. Industry-specific power supply development services
Different industries impose vastly different regulatory and environmental demands on power electronics. Our power supply development service is tailored to meet these strict vertical requirements.
3.1 Medical device power supply manufacturer capabilities
As a specialized medical device power supply manufacturer, we understand that patient safety is paramount. Medical equipment requires power supplies that comply with IEC 60601-1 (3rd/4th Edition) standards, specifically demanding 2x MOPP (Means of Patient Protection) and ultra-low leakage currents. We excel in designing the medical isolation power supply, ensuring robust galvanic isolation between the AC mains and patient-connected circuitry.
Furthermore, modern medical devices are highly software-driven. We integrate our power designs seamlessly with system controllers. Learn more about our holistic approach in our guide to medical device software development and PCB design services.
3.2 Industrial automation and manufacturing power supply design
An industrial automation power supply must survive harsh environments: extreme temperatures, heavy vibration, and severe electrical transients on the factory floor. Our manufacturing power supply design focuses on high MTBF (Mean Time Between Failures) and robust thermal management without relying on failure-prone cooling fans.
We frequently design systems that integrate directly into control panels. For insights into how we handle complex industrial power routing and protection, read about our circuit breaker panel design and ECAD/MCAD integration.
3.3 Automotive electronics power supply
The automotive electronics power supply faces unique challenges, such as load dumps, cold cranking, and strict EMC requirements (CISPR 25). We design ruggedized DC-DC converters and battery management interfaces that provide stable power to sensitive vehicle electronics, even under severe battery voltage fluctuations.
4. Our power supply customization service process
Our power supply customization service is a collaborative engineering journey. We don’t just take a spec sheet; we analyze your entire system architecture.
- Topology Selection: We select the optimal topology (e.g., LLC resonant, flyback, or forward converter) from our platform library. For applications requiring wide input voltage ranges, we specialize in advanced buck-boost converter design and PCB layout.
- ECAD/MCAD Co-Design: Power supplies must fit perfectly. We use integrated 3D modeling to ensure components clear your enclosure and thermal pathways are optimized.
- Prototyping & Pre-Compliance: We build rapid prototypes and subject them to in-house EMC pre-compliance testing, ensuring the design will pass formal certification without costly iterations.
5. Turnkey EMS: Integrating power into mechatronic systems
A power supply is only one piece of the puzzle. As a comprehensive Electronic Manufacturing Services (EMS) provider, TPS Elektronik goes beyond the PCB. We offer full mechatronic integration.
Once your customizable power supply solution is designed and manufactured, we can integrate it directly into your final product. Whether it involves wiring the power supply into a complex medical cart, integrating it with battery test systems, or mounting it within an industrial control cabinet, our turnkey mechatronics services reduce your supply chain complexity.
By handling both the custom power supply design and the final system assembly, we guarantee that the power unit performs flawlessly within its intended environment.
