Aerospace and defense electronics often operate under conditions that standard, off-the-shelf components were never designed to handle. Power systems may require unusual input or output voltages, specific dimensions, low weight, specialized insulation or environmental protection that cannot be achieved with a standard transformer. When a transformer has to fit within a tightly constrained enclosure while operating through vibration, temperature changes and electromagnetic interference, its design becomes part of the larger system engineering process.
At SI Manufacturing, we produce custom transformers and other magnetic components for aerospace and defense electronics, including applications involving airborne equipment, missiles, spacecraft and shipboard systems. Our experience allows us to work with engineers who need transformer designs that account for the electrical, physical and environmental requirements of their equipment.
Why Standard Transformers May Not Fit
A transformer has to match the electrical and physical requirements of the equipment around it. Aerospace and defense systems may have input and output voltage requirements that do not correspond to common commercial transformer ratings. The available installation space may also dictate a specific length, width, height, mounting arrangement or winding configuration.
Weight presents another consideration, particularly in airborne and space applications. Every component contributes to the overall system mass, so engineers may need to balance electrical capacity with the available space and weight budget.
The operating environment can be demanding as well. High vibration can place mechanical stress on windings and connections, while temperature extremes can affect insulation materials, electrical characteristics and heat dissipation. Electromagnetic interference may also need to be considered when a transformer operates near sensitive electronics.
For equipment used in mission-critical systems, dependable transformer performance is part of maintaining the intended function of the larger assembly.
Transformer Design Choices Affect Performance
Several design decisions influence how a transformer performs throughout its service life.
Core material affects magnetic characteristics, losses, operating temperature and the size of the transformer required for a given application. Selecting an appropriate core helps us balance electrical requirements with available space.
Winding configuration affects voltage transformation, current capacity, leakage characteristics and heat generation. Winding geometry and conductor selection also influence how the transformer handles mechanical and thermal stresses.
Insulation separates conductors and helps prevent electrical breakdown. The insulation system needs to match the voltage requirements and anticipated operating environment.
Encapsulation can provide additional protection around the transformer assembly. Depending on the application, encapsulation can help protect windings and other internal components from moisture, contaminants, vibration and environmental exposure. We offer vacuum or pressure multi-compound encapsulation options for demanding applications.
Thermal management is another important consideration. Transformers produce heat during operation and the design needs to account for how that heat moves away from the component. Managing temperature can help maintain electrical characteristics and reduce stress on insulation and other materials.
These decisions are interconnected. Changing the core, winding arrangement, insulation system or encapsulation method can affect the transformer’s size, temperature, electrical behavior and manufacturing process. We consider these factors together when developing a transformer around an application’s requirements.
From Design Assistance Through Production
At SI Manufacturing, we support custom magnetic component projects from design assistance through manufacturing and testing. We can work from customer drawings and specifications for build-to-print production while also supporting projects that require engineering input during development. Our documented capabilities include electrical, functional, visual, mechanical and environmental testing, along with first-article inspection when requested.
We maintain ISO 9001:2015 and AS9100D certifications and are ITAR registered. For applicable PCB assembly work, we can meet IPC J-STD-001 Class 3 requirements. We also work with customer-specified military and aerospace requirements where applicable.
This combination of engineering support, build-to-print manufacturing, qualification and environmental testing and production can be useful when a transformer has to meet requirements that go beyond a catalog component.
We have produced electronics and magnetic components for aerospace and defense applications ranging from airborne systems and missile programs to spacecraft and shipboard equipment. Our experience spans applications where electrical, physical, environmental and testing requirements need to be considered together.
If you are developing a transformer for an aerospace or defense application, send us your input and output voltages, power requirements, available size and weight, operating environment and required testing or qualification requirements. Our engineering team can review those requirements and discuss an appropriate manufacturing approach.