What is a Custom Power Supply: Components & What to Consider ?

Custom power supplies provide tailored solutions for unique performance, size, and efficiency requirements, making them ideal for various applications. At Phihong, we specialize in designing power supplies that meet your device’s specific needs.

Manufactured in ISO-certified facilities in Asia, our products adhere to the highest industry standards, including ISO 9001, 9002, ISO 13485, and ISO 14001. With advanced features like fast charging support, smart recognition technology, and modular designs, we deliver a competitive edge across industries, from consumer electronics to industrial applications.

Ready to find the perfect custom power supply for your needs? Reach out today for more information on product applications, pricing, and quantity details.

What is a Custom Power Supply?

A custom power supply is a tailored solution designed to meet specific performance, environmental, and integration requirements of a particular application or device. These power supplies are purpose-built to deliver the precise voltage, current, and performance characteristics that specialized systems need. Unlike standard modular options, custom power supplies are engineered to fit unique physical dimensions, address demanding environmental conditions, and achieve specific functional goals.

Ideal Applications of Custom Power Supply

Custom power supplies are particularly beneficial in scenarios where standard units fall short. They are ideal for applications requiring unique voltage outputs, specific physical dimensions, or operation in harsh and challenging environments.

Fields such as medical devices, aerospace, military, and specialized industrial equipment often rely on these tailored solutions to meet stringent performance and safety standards. For example, medical imaging devices require exact voltage regulation and minimal electrical noise to ensure accurate diagnostics, while aerospace and military systems demand robust, high-performance power solutions to withstand extreme conditions.

Beyond these specialized industries, custom power supplies also offer significant benefits in everyday applications, providing solutions for a wide range of common challenges. They are especially useful in scenarios where standard power supplies are either too large, inefficient, or unable to meet specific technical requirements. Some notable examples include:

• Battery Production: Ensuring precise charging and maintenance for advanced or experimental battery setups.
• LED Lighting Systems: Delivering tailored outputs to match high-performance LED arrays’ exact power and dimming needs.
• Medical and University Laboratories: Providing ultra-stable, low-noise power to maintain the accuracy and reliability of sensitive instruments.
• Low-Power AC to DC Conversion: Ideal for small-scale or niche applications where standard converters would be oversized or inefficient.
• Instrumentation: Supporting precision measuring devices with power supplies engineered for minimal electrical interference and stable output.

Custom Power Supply Solutions: Our Options

Industrial power supplies are built to meet the tough demands of industrial environments. Designed for durability, they can withstand extreme conditions like temperature fluctuations, humidity, and vibrations, while offering strong protection against surges, short circuits, and other electrical hazards. Here are the options we offer for tailored industrial power supply solutions:

Switching Power Supply Switching power supplies are highly efficient and compact, making them ideal for applications where space is limited and energy efficiency is a priority. These power supplies use switching regulators to convert electrical energy, minimizing heat and power loss. Customization can optimize their size, voltage, and efficiency to fit specific applications such as industrial automation, telecommunications, and consumer electronics.

AC-DC Power Supply AC/DC power supplies convert alternating current (AC) from the mains into direct current (DC) for electronic devices. They can be customized for various input and output voltages, currents, and power levels to match unique operational requirements. Applications like household devices, industrial machinery, and office equipment benefit from personalized solutions that enhance reliability and efficiency.

PoE Power Supply PoE power supplies deliver both power and data over a single Ethernet cable, reducing installation complexity. They are ideal for devices like IP phones, security cameras, and wireless access points. Custom PoE power supplies can be designed to meet specific wattage or voltage requirements and ensure seamless integration.

GaN Power Supply Gallium Nitride (GaN) is revolutionizing the power supply industry with its superior efficiency, smaller size, and lighter weight compared to traditional silicon. We leverage GaN technology to deliver compact, efficient power solutions for applications ranging from portable electronics to high-performance computing.

Medical Power Supply Medical power supplies are specifically engineered to comply with the stringent safety standards for patients and the performance standards of the healthcare industry. These include features like low leakage current, ultra-stable voltage outputs, and long operational lifespans. Custom designs ensure compatibility with equipment like imaging systems, diagnostic devices, and life-support machines.

Server Power Supply Server power supplies are engineered to deliver consistent, efficient power to data center equipment, ensuring optimal performance and reliability. They often feature redundant configurations, allowing for uninterrupted operation even if one power unit fails. Advanced designs incorporate high-efficiency components to minimize energy consumption and heat generation. Customization options enable alignment with specific server requirements, supporting various voltages and power levels.

Why Choose Phihong for Custom-made Power Supply?

From electrical performance to appearance, safety, and special features, we ensure the custom power supply aligns with your specific operational, environmental, and aesthetic needs.

Customized Electrical Performance for Every Need

Our custom power supplies provide tailored electrical specifications to ensure your system operates flawlessly, ideal for medical equipment and industrial tools requiring precise, efficient, and dependable power output.

With input voltages designed for global compatibility (100-240V AC) or specific regional needs, they are suitable for any market. Output voltages and currents are adjustable based on device requirements, ranging from standard (4V-24V) to higher demands, with current capacities up to 3A or more.

Our power supplies also support modern charging protocols like USB Power Delivery (PD), Quick Charge (QC), and even cutting-edge GaN systems, ensuring fast and efficient energy delivery. With conversion efficiencies of up to 95%, they reduce power loss and operating costs.

Flexible Appearance and Structure

Custom power supplies we offer don’t just perform well—they look and fit the part too. It is perfect for brands seeking a sleek, durable, and aesthetically aligned power solution.

From compact and ergonomic shapes that enhance portability to unique designs that distinguish your product, custom power supplies align seamlessly with your system’s design. Housing materials like PC/ABS blends provide heat resistance and durability, while customizable colors and finishes (smooth, matte, or metallic) ensure a visually appealing final product.

Custom plug designs include foldable or fixed options, compatible with various regional standards (US, EU, UK, AU, CN). Moreover, options like IP54-rated waterproof and dustproof housings make these power supplies impeccable for harsh or outdoor environments.

Advanced Interface Options

Our custom power supplies feature adaptable interfaces to support a wide range of devices.

Options include USB-A and USB-C ports for traditional and fast-charging compatibility, as well as multi-port designs for added convenience. For specialized applications, we can integrate unique connectors and high-quality cables made from durable materials like nylon braids or silicone. This solution is perfect for device manufacturers in need of proprietary connections or the ability to charge multiple devices simultaneously.

Engineered for Challenging Environments

Our custom power supplies are built to thrive in demanding conditions. With wide operating temperature ranges (-10°C to 70°C), drop resistance, and anti-interference features, they maintain performance and durability in the harshest environments. These capabilities make them well-suited for rugged industrial use, military operations, and outdoor applications.

Enhanced Safety and Protection Features

Safety is a core component of custom power supplies. Advanced protection mechanisms include Overvoltage (OVP), Overcurrent (OCP), Short-Circuit (SCP), and Over-Temperature Protection (OTP) to prevent damage to the power supply and connected devices. These supplies are without a doubt certified to meet international safety standards such as CE, UL, and FCC, ensuring compliance and reliability across global markets.

Special Features for Modern Convenience

What truly sets our custom power supplies apart are the innovative features we integrate. We offer fast charging support and compatibility for leading brands like Apple, Samsung, and Huawei, ensuring quick and efficient charging.

Our smart recognition technology automatically detects the power requirements of connected devices, optimizing efficiency with every use. The modular design, with replaceable plug modules, makes our power supplies an ideal choice for travel chargers, while LED indicators provide real-time feedback on charging status for added convenience.

What to Consider When Designing a Custom Power Supply

Designing a custom power supply requires careful consideration of several critical factors to ensure safety, efficiency, and reliability. Below are key aspects to address:

Regulatory Compliance for Safety

Ensuring compliance with safety standards is critical in power supply design to protect users and meet regulatory requirements. The International Electrotechnical Commission (IEC) establishes global safety standards for electronic products, which regional markets adapt to local needs—for example, the U.S. follows UL 62368-1. These standards address key safety considerations, including insulation, creepage distances, and protection against electric shock.

Certification organizations such as UL and TUV provide guidance to ensure power supplies meet the required specifications. Early integration of safety requirements into the design process helps minimize risks, streamline certification, and avoid severe consequences such as product recalls, legal penalties, or threats to user safety.

Heat Management

Efficient heat dissipation is essential for ensuring the longevity and optimal performance of a power supply. Components like transformers and semiconductors generate heat during operation, which, if not properly managed, can lead to thermal stress and failure.

 

Incorporating adequate cooling mechanisms, such as heatsinks and ventilation, helps in maintaining optimal operating temperatures. Proper thermal management not only enhances reliability but also ensures that the power supply meets safety standards related to temperature rise.

Energy Efficiency

High power conversion efficiency is crucial for reducing wasted heat in power supplies, improving system reliability, lowering operational costs, and enabling lighter, quieter designs. The International Efficiency Marking Protocol (IEMP), coordinated by the Department of Energy (DOE), sets the standard in America, with Level VI being the current requirement.

 

Employing topologies such as switch-mode power supplies (SMPS) can achieve higher efficiency compared to linear regulators. Prioritizing energy efficiency in the design phase ensures compliance with regulations and meets consumer expectations for sustainable products.

EMI/EMC Regulations

EMI (Electromagnetic Interference) and EMC (Electromagnetic Compatibility) are critical considerations for power supplies in the U.S. market. EMI refers to the unwanted electrical noise emitted by a device. EMC, on the other hand, ensures that a device can function correctly in its intended environment without causing or being affected by such interference. Non-compliance can disrupt the operation of nearby electronic devices and lead to regulatory penalties.

In the United States, the Federal Communications Commission (FCC) regulates EMI and EMC under FCC Part 15, which outlines rules for radio-frequency emissions and immunity for electronic devices.

Design considerations include proper PCB layout, shielding, and filtering components to mitigate EMI. Adhering to EMC standards is crucial for the reliable operation of both the power supply and surrounding electronics.

Future Scalability

Designing with future requirements in mind allows for scalability and adaptability. Anticipating potential increases in power demand or additional functionalities can save time and resources in the long run. Incorporating flexible design elements enables the power supply to accommodate future technological advancements and varying application needs.

Why Do You Need a Custom Power Supply?

Modular power supplies offer configurability to a certain extent, but they may not fully meet specific requirements, especially in demanding environments. They can also introduce challenges like connector failures and inefficiencies in certain systems. As a result, they may not always be the best fit for applications requiring customized or highly robust power solutions.

In contrast, custom power supplies are designed with precision to meet unique performance requirements, delivering tailored solutions that boost system reliability and efficiency. Here are more compelling reasons why a custom power supply might be the right choice for your needs.

Tailored Performance

A custom power supply is built specifically for your application. This means it can deliver the exact performance your system needs, like ultra-low noise, minimal leakage current, or precise voltage regulation, ensuring it works at its best. Unlike modular options, custom designs integrate seamlessly into your setup, improving overall efficiency and functionality.

Enhanced Reliability

Custom power supplies are engineered to perform reliably in demanding conditions, making them ideal for critical applications like medical facilities or rugged industrial environments. Their exceptional durability reduces the need for frequent replacements, ensuring long-term performance in extreme temperatures, high altitudes, or harsh operating conditions. With a tailored design, your equipment operates smoothly and consistently, minimizing the risk of unexpected failures.

Flexible Packaging

Custom designs allow for adjustments to size and shape, making them fit perfectly into your equipment. This flexibility means better use of space and a cleaner, more efficient, and compact system layout, which modular supplies often cannot achieve.

Reduced Costs and Components

Custom power supplies include only what you need, avoiding unnecessary features or parts. This can simplify the design, lower costs, and make the system easier to manage and maintain over time.

Components of the Power Supply

Designing a custom power supply involves several key components, each playing a crucial role in converting and regulating electrical energy. Here’s an overview of these elements and considerations for custom designs:

Transformer

A transformer is a crucial component in power supplies, responsible for adjusting voltage levels to suit different devices and providing isolation between input and output circuits. It operates on the principle of electromagnetic induction, transferring electrical energy between circuits without changing the frequency.

When designing a custom transformer, several factors are essential:

• Power Rating: Ensure the transformer can handle the maximum load to prevent overheating and ensure longevity.
• Turns Ratio: Determine the appropriate ratio of primary to secondary windings to achieve the desired voltage conversion.
• Thermal Management: Implement effective cooling solutions to dissipate heat generated during operation, maintaining performance and safety.

Rectifier

A rectifier is a vital component in power supplies, converting AC to DC, which is required by most electronic devices. It ensures a steady and reliable DC supply from an AC source, making it essential for powering sensitive systems. There are different types of rectifiers, such as half-wave, full-wave, etc. Half-wave rectifiers are simple but less efficient, while full-wave and bridge rectifiers offer higher efficiency and smoother output, which are suitable for most applications.

When designing a custom rectifier, it’s important to consider the diodes used, as they determine the voltage and current handling capacity. Proper selection ensures the rectifier can handle peak loads and maintain reliability. Moreover, the design must account for power loss and heat dissipation to ensure long-term performance.

Filter

A filter is also a critical part of a power supply, smoothing out the pulsating DC output from the rectifier into a steady voltage. It eliminates voltage ripple, which is essential for the stable operation of sensitive electronic devices. Filters typically use components like capacitors, inductors, or a combination of both to achieve this. Capacitors store and release energy to fill voltage gaps, while inductors resist changes in current, helping to stabilize the output.

Customizing a filter involves considering load requirements, voltage levels, and the acceptable ripple level for your application. The filter must be designed to handle the maximum current and voltage without compromising performance. Selecting and configuring the filter correctly ensures stable, noise-free power delivery, making it essential for systems that demand reliability and precision.

Regulator Circuits

A regulator circuit is a key component in a power supply that ensures a steady and reliable output voltage. It works by adjusting the voltage to a fixed level, even when the input voltage fluctuates or the load changes. This consistency is critical because many electronic devices need a stable voltage to function correctly. Without a regulator circuit, voltage swings could cause devices to perform poorly or even become damaged over time.

When designing a custom regulator circuit, there are a few things to consider. First, you’ll need to choose between linear and switching regulators. Linear regulators are simple and produce minimal noise, but they’re less efficient. Switching regulators, on the other hand, are more efficient and versatile, but they can introduce some electrical noise.

You also need to think about the dropout voltage, which is the minimum difference between the input and output voltage that the regulator needs to work properly. Thermal management is another crucial factor. Regulators can generate heat during operation, so proper cooling is essential to prevent overheating and maintain reliability. Finally, make sure the regulator can handle the maximum current your device will need under all conditions.

Tailored Power, Expertly Crafted – Choose Phihong as Your Custom Power Supply Manufacturer!

At Phihong, we specialize in providing custom power supplies designed to meet your unique operational needs. Whether you’re focused on safety, efficiency, aesthetics, or environmental durability, we create reliable solutions tailored specifically for your applications.

Our custom power supplies come with several advantages, including factory certifications and a comprehensive warranty to ensure peace of mind. Manufactured in ISO-certified facilities in Asia, we meet the highest industry standards, such as ISO 9001, 9002, ISO 13485, and ISO 14001, which, combined with our economies of scale, allow us to offer cost-effective solutions without compromising on quality.

If you’re looking for a custom power supply, we’re here to help. Whether it’s for a specific application/country, quantity, or pricing details, feel free to reach out. You can also click on each product category to learn more. Our expert team is always ready to assist you in finding the perfect power supply solution for your needs.