Flyback Transformer Manufacturer - Custom Ferrite Designs

Look for control of the two values that drift most easily: primary inductance and leakage inductance. That means consistent gap grinding, a fixed winding sheet and measurement of every unit. In-house winding, hipot testing on all pieces and batch traceability are also worth checking. NG Electronics is ISO 9001:2015 certified and tests each unit electrically before it leaves Pune.

Ungapped ferrite saturates at a very small magnetising current and stores little energy. Adding a gap lowers the effective permeability, so the core can carry the peak primary current without saturating, and most of the energy is held in the gap itself. The gap also makes inductance more repeatable, because it depends less on the permeability tolerance of the ferrite.

As a general guide, flyback converters are typically used up to roughly 150 W. Beyond that, the peak and RMS currents in the switch, the windings and the output capacitors become large, and the transformer grows quickly because it must store all the energy each cycle. Forward, push-pull or bridge converters are normally preferred at higher power.

Yes, and this is one of its main attractions. Extra secondaries are added on the same core, each with its own rectifier. The output connected to the feedback loop is regulated closely, while the others follow by turns ratio and vary with load. Coupling the secondaries tightly improves this cross-regulation; where an output must be precise, a small post-regulator is commonly added.

For custom designs, single-piece prototype samples are possible and about 10 pieces is a typical R&D quantity. Samples are typically ready within 7 to 10 working days. Production orders for custom parts typically start between 100 and 1,000 pieces, and a test certificate can accompany the delivery on request.