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The end of a year is always a bittersweet moment, often a time to reflect on what happened over the past 365 days, and look forward to what the future holds. With a new year quickly approaching, we wanted to take a look at what all happened over the last year at SI Manufacturing. 

Right at the start of the year, SI Manufacturing also announced our intention to become certified according to the CMMC framework. The Cybersecurity Maturity Model Certification was created by the Department of Defense to standardize and improve cybersecurity for any contractors working in military applications in some way. We have followed the framework closely to ensure our compliance and are on our way to becoming certified now that the CMMC has been finalized. 

Perhaps the biggest change for SI Manufacturing in 2025 comes from our acquisition by Payton Group. Not only did this shift open us up to a variety of new resources and capabilities, it also aligned with our company’s values. As a family-owned and operated manufacturer, SI has always taken care of our team members, fostering a family-oriented culture within our company. We are delighted to become part of a worldwide company that holds similar values of treating their team members as part of the family. 

Speaking of our SI family, we also want to share another bittersweet moment as our owner James ‘Bud’ Reed officially retires from the business after nearly 50 years growing the business as a second-generation leader. Bud Reed played a major role in getting SI Manufacturing to where we are today, and we wish him all the best in his retirement. 

Despite all of the changes and especially the worldwide turmoil that interrupted many manufacturing supply chains, SI Manufacturing continues to maintain its foundation as a family-focused and operated business serving some of the most rigorous markets across the globe. We are grateful to our partners, our customers, our suppliers, and especially our team members, for making 2025 an amazing year, and we look forward to what we will achieve together in 2026!

Precision is a crucial part of magnetic coil windings. Precision winding of the wire coil ultimately affects the performance, efficiency, and reliability of the component, be it a transformer, inductor, or power supply, which in turn can have a major impact on the performance of the larger, end-use assembly. And when it comes to manufacturing electronics for military and aerospace applications, good precision prevents critical equipment failures and ensures performance even in bad environments. 

At SI Manufacturing, we regularly manufacture custom magnetics that have to meet MIL standards for use in Defense equipment, aircraft, satellites, and even space exploration. And whether it’s a simple component or a full box build and wire harness assembly, oftentimes none of it would function to spec without expert precision winding of the magnetic coil. 

Why Precision Matters in Coil Windings

Windings are the most important part of any transformer, inductor, or similar magnetic component, serving as a medium for energy transfer, magnetic coupling, energy storage, and energy conversion depending on the part. It’s far more complex than just winding a wire around the core–proper configuration has a direct impact on electrical resistance, inductance, loss, thermal performance, and much more. 

By manipulating the number of windings around the core, the type and number of wire coils used, the shape of the winding itself, and even the distance between the individual windings, among many other factors, the manufacturer can adjust the performance of the magnetic component to the customer’s specifications. And because magnetics are so crucial to nearly every type of electronic assembly, precise coil windings even affect the function of end-use products and equipment.  

Precision Winding that Meets Military Standards

Military standards for custom magnetics, such as the MIL-STD-981 for Space Applications, lay out thorough guidelines and quality standards for every single aspect of magnetics manufacturing–including coil windings. In these types of applications, higher precision not only means better performance, but also mission-critical reliability, extended durability, reduced EMI and performance drift, and even the prevention of critical failures. 

At SI, we specialize in full electronics manufacturing that meets these types of rigorous standards. We manufacture magnetics of every size, description, encapsulation, and winding type, all of which go through required testing and quality inspections. All of our performance and quality examinations, including electrical, functional, visual, mechanical, and environmental testing, are completed in-house for improved production efficiency and consistent quality management, while meeting industry standards. 

Precision Winding and Electronic Contract Manufacturing from SI

Manufacturing complex precision magnetics and high-reliability electronic assemblies are an everyday occurrence here at SI, and we’ve been providing our expertise to Defense, Aerospace, and Industrial Equipment manufacturers since 1952. If you’re interested in working with us, don’t hesitate to contact us to request a quote or more information!

Recent events may have brought reshoring to the forefront of conversation in the manufacturing industries, but the trend towards building back up domestic manufacturing in the U.S. has been going on for the past few decades. As a manufacturing company based out of Anaheim, CA, the state providing the biggest contribution to the industry in the U.S., SI Manufacturing is here to help our partners in their reshoring and onshoring efforts with high-performance custom electronic solutions.

The Growing Benefits of Domestic Custom Electronic Solutions

While offshore manufacturing has long been the more popular option due to its lower upfront costs, domestic manufacturers have proven that they can offer just as much value, if not more. These are just a few of the advantages that domestic manufacturers like SI have to offer. 

Improved Supply Chain Resilience

The recent pandemic, changes in U.S. tariffs, and major geopolitical events, have all shown just how fragile global supply chains really are. Working with domestic contract manufacturers helps to avoid trade restrictions and tariffs, as well as supply constraints due to major geopolitical events and other related risks. 

Better Quality and Security

The U.S. tends to have much stronger quality management restrictions and standards for manufacturers than other major countries, and stronger regulations on cybersecurity, especially in industries like Defense–one of the major industries that SI serves. Having a domestic partner also makes it far easier to visit their facility and see their quality management and control teams in action, so that you can be sure you’ll get the quality you need. 

Faster Turnaround Times and Lower Shipping Costs

Another advantage of domestic suppliers is the geographical distance. Your products will be at far less risk of damage during shipping, and will arrive much more quickly. In addition, you won’t have to worry about expensive shipping and delivery costs that come from working with offshore manufacturers. 

Contributing to Local and Overall Growth of the U.S. Industry and Economy

Manufacturing jobs are a major part of many local communities and economies in the U.S. Working with domestic manufacturers helps to contribute to those communities and to the growth of the U.S.’s manufacturing sector. This also often makes your products more attractive to U.S. customers, who largely prefer ‘made in America’ goods. 

Custom Electronic Solutions from SI Manufacturing

SI has been in the industry for several years, serving some of the most demanding industries in the electronics sector of manufacturing from our facility in Anaheim, CA. We offer full-service solutions, including PCB manufacturing and assembly, prototyping, wire harness assemblies, box builds, custom power suppliers, quality control and performance testing, and much more. If you’re looking to reshore your electronic manufacturing needs, consider partnering with us–contact us today to request a quote and get started.

Traditionally, magnetics used in electronic systems have always involved a wire coil winding, which introduced some variability in their performance, no matter how precise the winding was. Planar magnetics, the latest innovation of magnetics design, offer a new way to achieve robust power, reliable performance, and higher power densities. Initially used mainly in extremely high-performance Defense and Aerospace applications, planar magnetics are seeing more and more widespread use across many industries. 

What makes planar magnetics different from traditional ones?

The biggest difference between planar and traditional magnetic components is the wire coil. Traditional transformers and inductors feature the tried and true coil windings around a central  material or air core. However, this design has always featured some amount of variability in performance. 

Planar magnetics feature multiple flat conductors, typically flat copper windings or multi-layer PCB configurations, rather than a wire coiled around a core. This design is much more compact and lightweight, as it eliminates the bulky material coil and multiple layers of insulation needed for traditional transformers or inductors. Planar-type transformers have been around for many years, but recent innovations in materials and manufacturing technologies have allowed manufacturers to take them to the next level.

As mentioned above, planar magnetics eliminate the need for all the layers of insulation required in traditional ones.They generate far less heat because there’s less space for heat to build up, plus their ‘windings’ are made on a material that can dissipate heat more effectively than traditional cores. Not only does this improve efficiency and reduce energy losses compared to traditional magnetics, the design also offers longer lasting durability and resistance. 

Common Applications of Planar Magnetics Technology

Planar magnetics are most often found in Defense and Aerospace systems, where performance is the utmost concern over initial costs. However, as planar magnetics become more easily manufacturable and available, they’ve also seen wider use in applications like electric and hybrid vehicles, renewable energy systems, industrial power supplies, and much more. They’ll likely see even more use in the future as the constant need for improved power, efficiency, and performance continues to grow. 

About SI Manufacturing

SI Manufacturing is an expert electronic contract manufacturing company specializing in demanding and custom electronics needs as well as full-service system solutions for Aerospace, Defense, and Industrial applications. Get in touch with us to learn more about what we have to offer.

Transformers have long played an important role in the world of electronics. No matter their size or type, transformers are crucial for balancing voltage levels between different devices, whether they’re massive transformers used in power grids or the small, customized transformers that we make here at SI Manufacturing for specialized system controls. Today, we’re going to explore exactly how a general transformer works and the basic principles behind its function. 

The Purpose of a General Transformer

No matter the specific type, design, or application of a transformer, all of them perform the same basic function: a transformer takes an input alternating current, and changes the voltage of that AC current to be either higher or lower, depending on its make-up. ‘Step-Up’ transformers increase the voltage, usually for more efficient transportation of electricity, while ‘Step-Down’ transformers lower the voltage, taking high voltage inputs and making them accessible for all of our electronic devices, no matter how big or small or simple or complex. 

How a Transformer Works

When an alternating current (AC) runs through a conductor, it generates a fluctuating magnetic field. Put a second conductor into the range of that magnetic field, and the fluctuations will induce a current in that additional conductor–a current that can be manipulated to produce a specific voltage. 

Transformers take advantage of that principle in order to control voltage levels. They consist of two conductive wire coils, primary and secondary, wrapped around a core. The AC current is introduced to the primary coil, which generates the magnetic field inducing a current in the secondary coil. That secondary coil then outputs a new voltage. 

A Matter of Ratios

The actual voltage level depends heavily on the ratio of windings–how many times a wire is wrapped around the core–between the primary and secondary wire coils. If the primary coil has, for instance, 100 turns around the core, and the secondary coil has 10, then the ratio would be 10:1, a ratio that then translates to how the output voltage differs from the input. To continue with the example, if 1,000 volts were applied to the primary coil, then the secondary coil would output 10 volts. 

And this works both ways too. The example above shows a step-down transformer, because it’s stepping down the voltage. Step-up transformers increase the voltage, so the secondary coil has more turns around the core than the primary. And because the ratio of turns translates exactly to the voltage ratio, transformers can be used to precisely manipulate input and output voltages. 

Further Possibilities for Customization

From there, transformers can be further manipulated and made to perform certain functions. Materials, core shape, coil windings, and more all contribute to the efficiency of the transformer and the precision of its functionality. There are plenty of ways that manufacturers can–and have–innovated on the general transformer for more complex applications and systems. 

About SI Manufacturing

SI Manufacturing is a full-service electronics manufacturing company specializing in custom magnetics, power supplies, and systems for some of the most demanding industries in the world. If you’re interested in working with us, give us a call! We’d be happy to learn more about your next project and how we can help.

When it comes to designing a custom transformer, there are several factors that you need to consider–including what type of wire you want to use for the coil. Coils for transformers tend to be made from either aluminum or copper wire, both of which have their advantages and disadvantages, as well as applications to which they’re better suited. Silver wire is also another option for custom transformers, offering even higher conductivity than copper, but tends to be expensive and only used in very specialized applications. 

This article offers a comprehensive comparison between copper and aluminum coils, and when each one is the best choice for a custom transformer. 

Aluminum: Light Weight and Efficient

Aluminum is a popular, cost effective choice for transformer coils, being lightweight and less dense than copper. This type of wire performs much more efficiently, with good storage capacity for heat in applications that generate low to medium heat. The use of aluminum coils reduces eddy currents and the risk of shorting, which is especially important for high-reliability applications. Aluminum is much more malleable compared to copper, easy to shape and experiences far less mechanical stress during the winding process, improving its life cycle. 

However, aluminum wire does have its disadvantages. At higher voltages, aluminum coils require more turns around the coil in order to achieve higher capacities, making them less compact. Though generally pretty durable, aluminum isn’t as resistant to corrosion and moisture as copper, and could require additional protection that will increase the coil’s density. It also tends to oxidize quickly when exposed to air, meaning it will need additional preventative measures and maintenance to protect the coil. 

Overall, aluminum wire coils are best suited for power distribution and relatively larger transformers where space constraints aren’t as big of a concern. 

Copper: Strong and Compact

Copper wire coils are best known for their mechanical strength and stability, being denser than aluminum but thinner, handling higher voltages with fewer turns around the coil. Copper offers much better electrical conductivity as well, carrying current with less resistive losses. Copper is easy to weld and fabricate, and tends to require less overall maintenance. It has high thermal conductivity as well, making it ideal for applications with higher heat generation than what aluminum wire can handle.

Like aluminum coils, copper does have its downsides. For one thing, it does tend to be more expensive, and its higher density means higher weight, a factor to keep in mind in applications where saving weight is crucial. Additionally, copper oxidizes very quickly, and once it starts, even parts that are protected will oxidize. 

Copper wire coils are overall the best choice for applications with high heat and higher current capacities. They’re also better suited to transformers that will be used in harsh or heavy-duty environments, being much stronger and more durable overall. 

SI Manufacturing: Your Partner for Full-Service Custom Transformer Manufacturing and More!

SI Manufacturing is a full-service electronics manufacturing company, helping our customers with everything from design to delivery and beyond. If you’re looking for a custom transformer manufacturer, consider partnering with us and get in touch with our team today!