COMPONENT DESIGN
Magnetic Component Manufacturing:
Elevating Performance Through Design By Scott Robinson, general manager, ETAL Group
H
ave you ever wondered what makes your smartphone charge so quickly or how your electric vehicle can go hundreds of miles on a single charge? It is largely thanks to the hidden powers of magnetic components; tiny but mighty transformers, chokes and the modern world.
However, these components are not your everyday off-the-shelf solutions. Each is crafted in meticulous detail and starts with the component design process. Think of this as the blueprint, where everything from the type of wire used to the precise shape of the components’ core is carefully considered. component design is not just a step in the manufacturing process, but the heart and soul of creating exceptional, bespoke magnetic components.
Think of magnetic component design like building a house. With a detailed plan, you know exactly what materials are needed, how to lay the foundations and how to avoid costly mistakes. Component design is our plan for creating magnetic components that transform the performance of everyday items. With careful, upfront planning, we can minimise wasted materials, reduce time the production process. For example, by choosing the correct materials for the job and designing how wires are wound, we can create components that use less energy, saving customers money and increasing
Technology is constantly evolving and, as our devices become smaller and increasingly complex, there is a desire to create lighter and more powerful magnetic components to keep up with demand. Component design innovative solutions that regular products can’t. We can experiment with new materials, explore new winding techniques and use computer simulations to design components
that outperform the competition. The aim is to push boundaries and create something truly unique.
Built to Last
Imagine building a bridge without considering the impact of the elements. It would not last long. Magnetic components must be strong and reliable to withstand the demands of real-world use. The design process allows us to consider how components react to vibration, extreme temperatures and electromagnetic interference. Computer simulations and rigorous testing identify the component is built to last and minimises downtime.
Building Trust
Component design is a roadmap for the manufacturing process. Each stage of the process is devised to ensure every component produced meets the highest standards of quality. There are rigorous quality control checks in place to minimise defects and ensure consistent performance. The production of reliable magnetic components that can perform and last the test of time enhances manufacturers’ reputations and
18 FEBRUARY 2025 | ELECTRONICS FOR ENGINEERS
builds trust among customers.
Streamlined Production and Faster Time to Market
manufacturing teams. It minimises confusion and errors, leading to a smoother and result, everyone knows their role and works together seamlessly to produce high-quality components. This streamlined approach allows manufacturers to deliver products to customers faster and bring these innovative magnetic components to market at speed.
In a world where technology is central to almost everything we do, magnetic components have a vital role to play, powering everything from electric toothbrushes and speakers to smartphones and electric vehicles. However, without components would fail to reach the level of performance required. Adopting a design-driven approach to magnetic component production enables manufacturers to embrace innovation and deliver cutting-edge solutions to meet the ever-evolving needs of customers and the industries they serve.
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