{"id":14467,"date":"2026-07-06T09:00:00","date_gmt":"2026-07-06T07:00:00","guid":{"rendered":"https:\/\/tps-elektronik.com\/?p=14467"},"modified":"2026-06-10T08:47:33","modified_gmt":"2026-06-10T06:47:33","slug":"tps-small-transformer-coil-winding-service-precision-miniature-coils-for-low-power-switch-mode-power-supplies-and-compact-dc-dc-converters","status":"publish","type":"post","link":"https:\/\/tps-elektronik.com\/en\/tps-small-transformer-coil-winding-service-precision-miniature-coils-for-low-power-switch-mode-power-supplies-and-compact-dc-dc-converters\/","title":{"rendered":"TPS Small Transformer Coil Winding Service: Precision Miniature Coils for Low Power Switch Mode Power Supplies and Compact DC\u2011DC Converters"},"content":{"rendered":"<article class=\"blog-post\" lang=\"en\"><header>\n<p>System integrators, panel builders, and procurement teams rarely fail because they lack a switching power supply design. They lose time\u2014and budget\u2014when the single custom magnetic component at the heart of that supply cannot be sourced from any catalog distributor in the exact form factor, inductance, and isolation voltage required. A standard off\u2011the\u2011shelf EFD15 flyback transformer might have the right turns ratio, but its physical height exceeds the 12\u202fmm enclosure limit. An alternative part might fit mechanically but introduces excessive leakage inductance that fails conducted emissions testing. Which forcing a costly and time\u2011consuming redesign cycle just weeks before the scheduled compliance submission.<br \/>TPS Elektronik\u2019s <strong>small transformer coil winding service<\/strong> built to eliminate that risk. By manufacturing custom miniature transformers, inductors, and chokes to exact electrical, mechanical, and thermal specifications. TPS bridges the gap between a proven reference design and a production\u2011ready power supply. This service specifically tailored for low\u2011power switch\u2011mode power supplies (SMPS) and compact DC\u2011DC converters up to approximately 100\u202fW. Where every millimeter of component height and every milliwatt of core loss must be accounted for.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/additional-services\/\">Request a miniature coil winding consultation \u2192<\/a><\/p>\n<\/header><nav class=\"toc\" aria-label=\"Table of contents\">\n<h2 id=\"toc-en\">Table of contents<\/h2>\n<ol>\n<li><a href=\"#en-why\">Why miniature custom winding matters for low\u2011power SMPS<\/a><\/li>\n<li><a href=\"#en-capability\">TPS small transformer winding capability<\/a>\n<ol>\n<li><a href=\"#en-geometry\">Supported geometries and core types<\/a><\/li>\n<li><a href=\"#en-wire\">Ultra\u2011fine wire handling and insulation<\/a><\/li>\n<\/ol>\n<\/li>\n<li><a href=\"#en-design\">Design considerations: leakage, coupling, and EMI<\/a><\/li>\n<li><a href=\"#en-quality\">Electrical testing and quality assurance<\/a><\/li>\n<li><a href=\"#en-compliance\">Compliance and safety: IEC\u202f62368\u20111, reinforced isolation, and EMC<\/a><\/li>\n<li><a href=\"#en-app\">Application examples: isolated DC\u2011DC, gate drive, and auxiliary supplies<\/a><\/li>\n<li><a href=\"#en-rfq\">RFQ checklist for miniature transformer winding<\/a><\/li>\n<li><a href=\"#en-faq\">FAQ<\/a><\/li>\n<\/ol>\n<\/nav>\n<section id=\"en-why\">\n<h2>1. Why miniature custom winding matters for low\u2011power SMPS<\/h2>\n<p>In a typical 20\u202fW isolated flyback converter, the power transformer is simultaneously the bulkiest, heaviest, and most electromagnetically critical component on the PCB. It determines the converter\u2018s efficiency, its electromagnetic interference (EMI) signature, its maximum ambient operating temperature. And most critically for compact designs \u2014 its total height above the board. A catalog transformer selected from a distributor\u2019s limited range almost always compromises at least one of these parameters.<\/p>\n<p>A <strong>miniature transformer winding service<\/strong> avoids these compromises by starting from the electrical specification and designing the magnetic assembly outward: selecting the smallest core that can handle the required power throughput without saturation. Which specifying the magnet wire gauge that minimizes DC resistance while fitting within the bobbin window, and arranging the winding layers to minimize leakage inductance and interwinding capacitance. The resulting component is a fully functional power transformer that fits the available PCB footprint and height budget exactly. While meeting the efficiency and EMI targets defined in the product specification. TPS\u2018s wider expertise in this area detailed in our comprehensive overview of <a href=\"https:\/\/tps-elektronik.com\/en\/comprehensive-electronic-design-services-complete-solutions\/\">electronic design services for complete solutions.<\/a> Which covers how custom magnetics integrate into broader development programs.<\/p>\n<\/section>\n<section id=\"en-capability\">\n<h2>2. TPS small transformer winding capability<\/h2>\n<p>TPS Elektronik operates precision coil winding equipment capable of producing miniature transformers with core dimensions as small as approximately 8\u202fmm (e.g., EE8.3, EP7, or small toroidal cores). The service covers the full range of low\u2011power SMPS topologies: flyback, forward, push\u2011pull, half\u2011bridge, and resonant LLC converters. Every winding project begins with a DFM (Design for Manufacturability) review that verifies the electrical specification against the mechanical constraints of the selected core and bobbin.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-14602\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/Precision-Miniature-Transformer-Coil-Winding-SMPS-Ferrite-Core-CNC-Machine-\u2013-TPS-Elektronik-1.jpg\" alt=\"Precision Miniature Transformer Coil Winding SMPS Ferrite Core CNC Machine \u2013 TPS Elektronik Pr\u00e4zisions-Miniaturtransformator-Spulenwicklung SMPS Ferritkern CNC\u2011Maschine \u2013 TPS Elektronik\" width=\"1920\" height=\"1078\" \/><\/p>\n<h3 id=\"en-geometry\">2.1 Supported geometries and core types<\/h3>\n<p>TPS winds on a wide variety of miniature ferrite core geometries. Each offering a different balance of power handling, shielding, and height profile. The table below summarizes the typical applications:<\/p>\n<ul>\n<li><strong>EE, EF, and EFD cores<\/strong>: These are the workhorse geometries for flyback and forward converters. Which offering moderate power handling (5\u201350\u202fW) with a low\u2011profile design.<\/li>\n<li><strong>EP and EPC cores<\/strong>: With their round center leg, these cores are ideal for applications where a compact footprint and good magnetic shielding are required.<\/li>\n<li><strong>RM and P cores (Pot Cores)<\/strong>: Offering the best self\u2011shielding, these commonly selected for low\u2011noise applications like precision analog supplies and sensitive sensor circuits.<\/li>\n<li><strong>Toroidal cores<\/strong>: Used for common\u2011mode chokes, current transformers, and where the absolute minimum height and lowest radiated field needed.<\/li>\n<li><strong>Planar cores (e.g., E\u2011I, E\u2011E planar)<\/strong>: Integrated with PCB windings for ultra\u2011low\u2011profile designs.<\/li>\n<\/ul>\n<p>For each geometry, TPS selects the appropriate ferrite material. Typically MnZn power ferrites such as 3C90, 3C94, N87, or N97 \u2014 based on the operating frequency (20\u202fkHz to several MHz), peak flux density, and required core loss characteristics. For higher\u2011frequency GaN\u2011based converters operating above 1\u202fMHz, low\u2011loss materials such as 3F4 or N49 are selected. TPS\u2019s capabilities in designing and manufacturing these components also supported by its broader experience in <a href=\"https:\/\/tps-elektronik.com\/en\/comprehensive-electronic-design-services-supply-chain-solutions\/\">supply chain solutions for electronic design.<\/a> Which ensuring material availability for both prototype and production volumes.<\/p>\n<h3 id=\"en-wire\">2.2 Ultra\u2011fine wire handling and insulation<\/h3>\n<p>Miniature transformers for sub\u201120\u202fW converters typically use magnet wire in the range of 0.05\u202fmm to 0.3\u202fmm diameter (AWG\u202f44 to AWG\u202f29). Handling wire below 0.1\u202fmm demands precise tension control to avoid wire stretch or breakage during winding. TPS\u2018s CNC winding equipment maintains calibrated tension across all spindles. And the wire insulation type \u2014 polyurethane (solderable, 130\u202f\u00b0C), polyester (155\u202f\u00b0C). Or polyimide (220\u202f\u00b0C) \u2014 selected based on the thermal class required by the application.<\/p>\n<p>For transformers requiring reinforced isolation \u2014 such as those used in medical power supplies or isolated gate drivers. TPS applies inter\u2011layer insulation tape (typically polyimide or polyester film) and margin tape to meet the creepage and clearance distances specified by IEC\u202f62368\u20111 or IEC\u202f60601\u20111. The insulation system designed with a triple\u2011insulated wire strategy (supplementary or reinforced insulation) if the bobbin geometry does not provide sufficient creepage with standard magnet wire. Which ensuring compliance with safety standards. These design practices are a core part of TPS\u2019s approach to <a href=\"https:\/\/tps-elektronik.com\/en\/incoming-goods-inspection-production-line-efficiency\/\">quality and efficiency in production<\/a>.<\/p>\n<\/section>\n<section id=\"en-design\">\n<h2>3. Design considerations: leakage, coupling, and EMI<\/h2>\n<p>In a compact flyback converter, leakage inductance is the silent enemy. It stores energy that is not transferred to the secondary, dissipating it in a snubber circuit or, worse, causing voltage overshoot on the primary switch. A miniature transformer with poor coupling (low primary\u2011to\u2011secondary coupling coefficient) may generate enough common\u2011mode noise through interwinding capacitance to fail conducted EMI limits on the first test.<\/p>\n<p>TPS engineers address these issues at the winding design stage. Leakage inductance is minimized through interleaved winding techniques \u2014 splitting the primary into two layers that sandwich the secondary \u2014 or through the use of a foil winding for the secondary in very low\u2011profile designs. Interwinding capacitance is controlled by selecting the insulation thickness and the winding arrangement (e.g., a Z\u2011winding pattern instead of a simple layer\u2011by\u2011layer approach). These design optimizations, along with the broader manufacturing capabilities, are part of the integrated approach described in our <a href=\"https:\/\/tps-elektronik.com\/en\/case-studies\/comprehensive-electronic-design-services-procurement-solutions\/\">procurement solutions case study<\/a>.<\/p>\n<\/section>\n<section id=\"en-quality\">\n<h2>4. Electrical testing and quality assurance<\/h2>\n<p>Every miniature transformer wound by TPS undergoes 100\u202f% electrical testing before it leaves the production floor. The standard test protocol includes inductance and turns ratio measurement, leakage inductance, DC winding resistance on all windings, and hipot (high\u2011potential) testing from winding\u2011to\u2011winding and winding\u2011to\u2011core at the specified isolation voltage. A documented test report with measured values accompanies every production lot.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-14612\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/\u7ebf\u57081.jpg\" alt=\"transformer coil winding\" width=\"1920\" height=\"1280\" srcset=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/\u7ebf\u57081.jpg 1920w, https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/\u7ebf\u57081-600x400.jpg 600w\" sizes=\"(max-width: 1920px) 100vw, 1920px\" \/><\/p>\n<p>For applications where partial discharge (PD) testing is required \u2014 such as medical devices or high\u2011reliability industrial equipment \u2014 TPS can perform PD testing to verify the absence of void defects in the insulation system, typically at test voltages 1.25 to 1.5 times the rated working voltage. The lot traceability system, connected to the practices detailed in our guide on <a href=\"https:\/\/tps-elektronik.com\/en\/inventory-management-for-electronics-component-stock\/\">inventory management for electronics<\/a>, ensures full material and process traceability for each batch of magnetic components.<\/p>\n<\/section>\n<section id=\"en-compliance\">\n<h2>5. Compliance and safety: IEC\u202f62368\u20111, reinforced isolation, and EMC<\/h2>\n<p>Any transformer that bridges a safety isolation barrier must comply with the relevant product safety standard. For industrial and IT equipment, <a href=\"https:\/\/webstore.iec.ch\/en\/publication\/69308\" target=\"_blank\" rel=\"noopener noreferrer nofollow\">IEC\u202f62368\u20111<\/a> is the governing standard, defining requirements for electrical shock, fire, mechanical, and thermal hazards. For medical applications, IEC\u202f60601\u20111 applies, with stricter limits on leakage current and insulation thickness.<\/p>\n<p>TPS designs miniature transformers to meet these standards by specifying the correct insulation materials, verifying creepage and clearance distances against the working voltage, and performing the required dielectric strength and partial discharge testing. A Declaration of Conformity referencing the applicable standards is provided with each production lot. TPS also considers the role of the transformer in the overall EMC performance of the end product; while the transformer is a passive component in the EMI path, its parasitic capacitances and core properties significantly influence conducted emissions, a topic explored further in our resources on <a href=\"https:\/\/tps-elektronik.com\/en\/improve-production-efficiency-incoming-goods-inspection-line-optimization\/\">improving production efficiency through inspection<\/a>.<\/p>\n<\/section>\n<section id=\"en-app\">\n<h2>6. Application examples: isolated DC\u2011DC, gate drive, and auxiliary supplies<\/h2>\n<p>Miniature wound transformers and inductors from TPS are found in a variety of compact power conversion applications:<\/p>\n<ul>\n<li><strong>Isolated DC\u2011DC converters<\/strong>: Brick and SIP\u2011format isolated converters (1\u201330\u202fW) for industrial, medical, and railway power supplies, where reinforced isolation and compact size are paramount. These designs often use EFD, EP, or planar cores.<\/li>\n<li><strong>Isolated gate drivers<\/strong>: Pulse transformers for IGBT, MOSFET, and SiC gate drive circuits, where low interwinding capacitance, high dv\/dt immunity, and consistent turns ratio are critical for safe switching. Toroidal or small RM cores are typical choices.<\/li>\n<li><strong>Auxiliary power supplies<\/strong>: Standby flyback converters delivering a few watts from a high\u2011voltage DC bus, where a custom EE8 or EF12 transformer delivers the required bias voltage in a minimal footprint.<\/li>\n<li><strong>Isolated sensors and signal conditioning<\/strong>: Miniature current transformers and isolation transformers for analog signal chains, where accuracy and linearity are essential.<\/li>\n<\/ul>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-14607\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/IEC-62368\u20111-Certified-Miniature-Transformer-Coil-Label-Safety-Compliance-Documentation-\u2013-TPS-Elektronik-5.jpg\" alt=\"IEC 62368\u20111 Certified Miniature Transformer Coil Label Safety Compliance Documentation \u2013 TPS Elektronik IEC 62368\u20111 Zertifizierte Miniaturtransformatorspule Etikett Sicherheitskonformit\u00e4t Dokumentation \u2013 TPS Elektronik\" width=\"1920\" height=\"1078\" \/><\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/additional-services\/\">Discuss your miniature transformer requirements with TPS \u2192<\/a><\/p>\n<\/section>\n<section id=\"en-rfq\">\n<h2>7. RFQ checklist for miniature transformer winding<\/h2>\n<ul>\n<li><strong>Electrical specification<\/strong>: Nominal input and output voltage, switching frequency, output power, target efficiency.<\/li>\n<li><strong>Inductance and turns ratio<\/strong>: Primary inductance, leakage inductance limit, turns ratio (NP:NS:NAux).<\/li>\n<li><strong>Core preference<\/strong>: Preferred core type\/size or a maximum mechanical envelope (L\u202f\u00d7\u202fW\u202f\u00d7\u202fH in mm).<\/li>\n<li><strong>Isolation requirements<\/strong>: Functional, basic, or reinforced insulation; working voltage and required test voltage.<\/li>\n<li><strong>Termination<\/strong>: Through\u2011hole pins (lead spacing), SMD pads, or flying leads with specified length.<\/li>\n<li><strong>Applicable standards<\/strong>: Safety standard (IEC\u202f62368\u20111, IEC\u202f60601\u20111) and any required certifications.<\/li>\n<li><strong>Quantities and schedule<\/strong>: Prototype, pilot, and series volumes with target delivery dates.<\/li>\n<li><strong>Documentation<\/strong>: Required test reports and certificates.<\/li>\n<\/ul>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/additional-services\/\">Submit your miniature transformer RFQ \u2192<\/a><\/p>\n<\/section>\n<section id=\"en-faq\">\n<h2>8. FAQ<\/h2>\n<p><strong>What is the smallest transformer core TPS can wind?<\/strong><br \/>TPS winds cores down to approximately 8\u202fmm in size (e.g., EE8.3, EP7), using ultra\u2011fine wire with precise tension control. The practical minimum depends on the number of windings, turns ratio, and isolation requirements.<\/p>\n<p><strong>Can TPS wind triple\u2011insulated wire for reinforced isolation?<\/strong><br \/>Yes. TPS regularly winds transformers using triple\u2011insulated wire (TEX\u2011E, TIW\u2011B, etc.) to achieve reinforced isolation in compact bobbin sizes where standard margin tape does not provide enough creepage distance.<\/p>\n<p><strong>Does TPS provide prototype quantities for design validation?<\/strong><br \/>Yes. TPS supports prototype builds with short lead times. Prototypes are wound on the same equipment used for series production, ensuring that the validated performance is reproducible in volume.<\/p>\n<p><strong>How does TPS ensure consistent transformer performance across production batches?<\/strong><br \/>TPS uses calibrated CNC winding equipment, documented setup procedures, and 100\u202f% electrical testing. Lot traceability and First Article Inspection (FAI) are standard, ensuring consistency between prototype and production.<\/p>\n<p><strong>Where can I learn more about TPS\u2019s broader electronic design and manufacturing capabilities?<\/strong><br \/>Visit the <a href=\"https:\/\/tps-elektronik.com\/en\/services\/additional-services\/\">TPS additional services page<\/a>, or read about our <a href=\"https:\/\/tps-elektronik.com\/en\/comprehensive-electronic-design-services-complete-solutions\/\">comprehensive electronic design services<\/a> and <a href=\"https:\/\/tps-elektronik.com\/en\/inventory-management-for-electronics-and-packaging-services\/\">inventory management solutions<\/a>.<\/p>\n<\/section>\n<footer style=\"background: #2d5797; padding: 30px; border-radius: 14px; margin-top: 40px;\">\n<p style=\"color: #ffffff; font-size: 16px; line-height: 1.6; margin: 0;\"><strong>Ready to replace a compromise catalog part with a custom miniature transformer that fits perfectly?<\/strong><br \/>Contact TPS Elektronik for a precision coil winding service that delivers the exact inductance, form factor, and isolation your low\u2011power SMPS or DC\u2011DC converter demands.<br \/><a style=\"color: #ffffff; font-weight: 600; text-decoration: underline; display: block; margin-top: 10px;\" href=\"https:\/\/tps-elektronik.com\/en\/services\/additional-services\/\">Request your miniature transformer coil winding consultation \u2192<\/a><\/p>\n<\/footer><\/article>\n\n<style id=\"wpforms-css-vars-4659-block-9874c321-366b-4304-8e69-7a7b433e9a07\">\n\t\t\t\t#wpforms-4659.wpforms-block-9874c321-366b-4304-8e69-7a7b433e9a07 {\n\t\t\t\t--wpforms-field-size-input-height: 43px;\n--wpforms-field-size-input-spacing: 15px;\n--wpforms-field-size-font-size: 16px;\n--wpforms-field-size-line-height: 19px;\n--wpforms-field-size-padding-h: 14px;\n--wpforms-field-size-checkbox-size: 16px;\n--wpforms-field-size-sublabel-spacing: 5px;\n--wpforms-field-size-icon-size: 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They lose time\u2014and budget\u2014when the single custom magnetic component at the heart of that supply cannot be sourced from any catalog distributor in the exact form factor, inductance, and isolation voltage required. A standard off\u2011the\u2011shelf EFD15 flyback transformer\u2026 <a href=\"https:\/\/tps-elektronik.com\/en\/tps-small-transformer-coil-winding-service-precision-miniature-coils-for-low-power-switch-mode-power-supplies-and-compact-dc-dc-converters\/\">Read More &raquo;<\/a><\/p>\n","protected":false},"author":9,"featured_media":14612,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[57],"tags":[],"class_list":["post-14467","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog-content"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.9 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>TPS Small Transformer Coil Winding Service: Precision Miniature Coils for Low Power Switch Mode Power Supplies and Compact DC\u2011DC Converters - TPS<\/title>\n<meta name=\"description\" content=\"TPS small transformer coil winding service delivers precision miniature coils for low power SMPS and compact DC\u2011DC converters. 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