Consultancy · Converter Development

Power converters engineered for efficiency, control & reliability

We design AC-DC, DC-AC, and DC-DC converters that perform in the real world — topology selection, magnetics, closed-loop control, simulation, prototyping, and efficiency & EMI testing. A simulation-first workflow built on the same power-electronics engineering we teach and ship, from 12 W to 2 kW.

AC·DC·AC Topologies Simulation-First Magnetics & Control EMI-Aware
12W–2kWPower range experience
AC·DC·ACConverter topologies
>90%Efficiency targets
Sim→BenchValidated designs
What We Deliver

Complete converter engineering, from topology to tested hardware

Power stage, magnetics, control, thermal, and EMI are engineered together — because a converter only works when every part of it works with the others.

Topology & Architecture

Buck, boost, buck-boost, SEPIC/Ćuk, flyback, forward, LLC, phase-shift, PFC front-ends, and inverters — chosen for your power, isolation, and efficiency targets.

Magnetics & Power Stage

Inductor and transformer design (core, turns, air gap, losses) with switch and diode selection, gate drive, and snubbers designed as one power stage.

Closed-Loop Control

Voltage- and current-mode control, compensator design, and stability (bode, phase margin) validated in simulation for clean, robust regulation.

Thermal & Reliability

Loss budgeting, heatsinking, and derating so the converter runs cool and lasts under real load, ambient, and stress conditions.

EMI/EMC-Aware Design

Layout, filtering, and switching strategy that keep conducted and radiated emissions in check and move you toward pre-compliance.

Testing & Efficiency

Measured efficiency curves, line/load regulation, ripple, and thermal data against targets — with iteration until the numbers hold.

Our Process

A clear, six-step path from spec to a tested converter

Predictable stages, checkpoints you can review, and a measured, working converter at the end.

Engineers defining converter specifications — input/output voltage, power, and efficiency targets — on a whiteboard
01
Step 01 · Requirements

Requirements & Specs

Input and output voltage range, power level, isolation, efficiency, size, and environment are captured into a clear, testable specification.

  • Input/output range & power defined
  • Isolation, efficiency & size targets
  • Environment & standards noted
Power converter topology schematic on screen during topology selection and trade-off study
02
Step 02 · Topology

Topology Selection

The right converter topology is chosen through a trade-off study and a feasibility check against your targets before any detailed design.

  • Buck / boost / LLC / flyback evaluated
  • Trade-off: efficiency, cost, size
  • Topology confirmed vs. targets
Converter simulation showing switching and control waveforms during design validation
03
Step 03 · Simulation

Simulation & Control Design

Power stage, magnetics, and closed-loop control are designed and validated in simulation — waveforms, efficiency, and stability — before hardware.

  • Power stage & magnetics sizing
  • Control loop & stability (bode)
  • Waveforms verified before hardware
Custom converter PCB with transformer, inductor, and power MOSFETs during prototype build
04
Step 04 · Prototype

Prototype & Magnetics

PCB layout, magnetics build, component sourcing, assembly, and the first power-up and bring-up of a real, working converter.

  • PCB layout & magnetics build
  • Sourcing & assembly
  • First power-up & bring-up
Bench testing a converter prototype with an oscilloscope and power analyzer for efficiency and EMI
05
Step 05 · Validation

Test, Efficiency & EMI

Bench testing for efficiency, regulation, ripple, thermal, and EMI — iterating until the converter meets every target.

  • Efficiency, regulation & ripple
  • Thermal & protection checks
  • EMI pre-compliance & iteration
Power4All team handing over converter documentation, schematics, and test data to a client
06
Step 06 · Delivery

Delivery & Documentation

Reports, schematics, magnetics details, BOM, PCB files, and measured data are handed over with a walkthrough so you can move forward with confidence.

  • Reports, schematics & magnetics
  • BOM, PCB files & test data
  • Walkthrough & complete handover
AC / DC Input Source Power Stage Switches + magnetics Filter LC / EMI Regulated Output Load Controller PWM + protection gate sense / feedback
Simulation-first: we validate the full closed-loop converter — input, power stage, magnetics, filter, control, and feedback — before building hardware.
What You Receive

A converter you can measure, defend, and build

Every engagement ends with a tangible package — the design intelligence, the hardware, and the measured evidence that it performs, ready for your next step toward a product.

  • Simulation reports with waveforms & results
  • Schematics and design calculations
  • Magnetics design (core, turns, gap)
  • PCB layout and manufacturing files
  • Bill of materials (BOM)
  • Working prototype and bring-up notes
  • Measured efficiency / thermal / EMI data
  • Documentation & handover
Close-up of a custom power converter PCB with transformer, inductor, and power MOSFETs

Engineered for efficiency & reliability

  • Loss-budgeted for high efficiency
  • Thermal and derating considered from day one
  • EMI-aware layout and filtering
  • Clean, reviewable design and documentation
  • A clear path from prototype toward production
Inside The Work

From topology sketches to bench-measured converters

A look at how converters actually take shape — selection, simulation, prototyping, and measurement.

Where It's Used

Converters for products, energy systems, and research

SMPS & adaptorsCompact, efficient AC-DC and DC-DC supplies for products and instruments.
Battery chargers (12W–2kW)Charge-profile and protection-aware converter stages for battery systems.
EV & mobility powerOn-board and DC-DC conversion for electric vehicles and light mobility.
Solar & renewable / MPPTDC-DC and inverter stages with maximum-power-point tracking.
Motor-drive & inverter stagesDC-AC inverters and drive front-ends for motion and power systems.
Lab & instrumentation suppliesProgrammable, clean, well-regulated supplies for benches and test setups.
Why Power4All

A team that simulates, builds, and teaches converters every day

Power4All is a power-electronics education and engineering platform — so your converter is guided by people who live in both the theory and the hardware.

Simulation-first proof

We build our own converter simulators and virtual labs, so your design is validated and visualized before hardware — cutting cost and risk.

Real converter depth

AC-DC, DC-DC, and DC-AC across many topologies from 12W to 2kW — practical converter experience, not just slides.

Magnetics + control together

Power stage, magnetics, and closed-loop control are designed as one system, so regulation and efficiency actually hold up.

Efficiency & EMI focus

We design and measure for efficiency, thermal margin, and EMI so the converter is production-minded, not just functional.

Education-grade documentation

Because we teach, we explain. You get clear reports and documentation your team or examiner can actually follow.

Built to iterate

Converters rarely hit spec on the first build. We plan for measurement, refinement, and a second pass so the result truly meets target.

FAQ

Converter development — common questions

AC-DC front-ends and rectifiers (including PFC), the full range of DC-DC converters (buck, boost, buck-boost, SEPIC, Cuk, flyback, forward, LLC, and phase-shift), and DC-AC inverters — typically from 12W to 2000W for products, labs, and academic work.
We match the topology to your input and output range, power level, isolation needs, efficiency target, size, and cost. A short trade-off study plus simulation confirms the best choice before any hardware is built.
Yes. Inductor and transformer design — core, turns, air gap, and loss estimation — is part of the work, alongside the power stage, gate drive, sensing, protection, and closed-loop control.
Absolutely. We analyse and simulate your current design, then re-engineer the power stage, magnetics, layout, and control to improve efficiency, thermals, and conducted/radiated emissions toward pre-compliance.
Simulation and design reports, schematics and calculations, magnetics design, PCB layout and BOM, a working prototype, measured efficiency/thermal/EMI data against targets, and complete documentation for handover.
Share your specifications — input and output voltage, power, isolation, efficiency and size targets, constraints, and timeline — through the consultancy request form. We review it and send back a clear scope and path.
Start Your Converter

Need a converter designed or improved?

Tell us your input and output voltage, power, isolation, efficiency target, and timeline. We'll propose the right topology and a clear path for simulation, prototyping, testing, and delivery.