Our Design &
Manufacturing Process
Altran designs and manufactures custom transformers and inductors for demanding industrial, medical, and high-reliability applications. Our vertically integrated process, from engineering through testing, ensures consistent performance, regulatory compliance, and scalable production.
1. Requirements & Initial Concept
Every project begins with a detailed review of the customer’s application requirements. Core electrical specifications include input voltage and frequency, output voltages and currents for single or multiple secondaries, and total power ratings expressed in VA or watts. Environmental and mechanical considerations—such as operating temperature range, altitude, humidity, size constraints, mounting method, and applicable regulatory standards (UL, CSA, CE, or medical certifications)—are defined early to ensure the design aligns with real-world operating conditions.
Design priorities are then established, including efficiency targets, acceptable noise and hum levels, thermal performance, and cost objectives. Customers may provide complete drawings for build-to-print programs or work directly with our engineering team to develop a fully custom solution. Expected production volume further influences the project approach, as the development path for a single prototype differs significantly from that of a low-volume or high-volume production run.
2. Design & Engineering
Altran’s engineers translate customer requirements into robust electrical and mechanical designs. Core materials are selected based on performance and application needs, including laminated steel cores, toroidal cores, and ferrite materials for high-frequency designs. Engineers calculate winding turns, turn ratios, and magnetic operating points, and select conductor sizes based on current requirements, allowable temperature rise, insulation system limits, and available winding window fill.
The winding structure is then defined, including primary-to-secondary stacking order, multiple secondary configurations, and the integration of electrostatic shields where required. Mechanical design considerations include mounting hardware, PCB pins or lead exits, terminal arrangements, shielding, and potting provisions.
Thermal modeling is performed to predict temperature rise under rated conditions, accounting for copper losses, core losses, and cooling methods. Insulation systems are selected to meet voltage, temperature, and lifetime requirements. Final compliance reviews verify creepage and clearance distances and confirm alignment with UL, CSA, CE, and other applicable industry standards before designs are released to production.
3. Core Preparation & Coil Winding
Core preparation begins with the precise stacking of laminated magnetic cores in interleaved patterns to minimize losses and reduce audible vibration. These assemblies may include common lamination geometries such as EI, UI, DU, and EE cores, depending on the application. Ferrite cores are also offered as an option for high-frequency and switch-mode designs. Laminations are clamped to maintain structural integrity and consistent magnetic performance. Toroidal cores are inspected for dimensional accuracy, material consistency, and surface integrity before technicians apply the required insulation layers.
For designs requiring controlled inductance or reduced saturation, calibrated air gaps are introduced with tight process control. Technicians then program computer-controlled winding equipment with exact turn counts, layer structures, winding direction, and tension parameters. Primary and secondary windings are applied to bobbins or toroidal cores using controlled tension to prevent conductor damage and ensure uniform layering. Insulation materials—including tape, paper, or film—are placed between windings to maintain required isolation and dielectric strength throughout the assembly.
4. Impregnation, Potting, & Final Assembly
Wound assemblies are impregnated using vacuum or pressure varnish processes to ensure complete penetration throughout the winding structure. After impregnation, units are cured in controlled ovens to lock windings in place, enhance thermal conductivity, and significantly reduce mechanical vibration and audible hum.
For applications requiring additional environmental or mechanical protection—such as medical, audio, or harsh-environment designs—units may be potted using epoxy or polyurethane compounds. Potting improves insulation integrity, moisture resistance, and long-term reliability.Final assembly includes the installation of mounting brackets, terminal boards, shields, and protective covers as required. Each unit is labeled with part numbers, electrical ratings, and applicable regulatory markings, including UL, CSA, and CE certifications where applicable. All assembly operations follow documented work instructions to ensure consistency, repeatability, and full traceability.
5. Quality Control & Testing
Every transformer and inductor produced at Altran undergoes comprehensive electrical testing. Continuity testing verifies winding integrity, while insulation resistance testing confirms isolation between windings and from windings to the core. Hi-pot dielectric testing applies elevated voltages between windings for specified durations to validate insulation strength and detect any potential breakdown paths.
Performance testing includes no-load measurements to evaluate core losses and output voltages at nominal input conditions, followed by load testing to verify regulation, temperature rise, and performance at rated current. Polarity and turns ratio are confirmed using precision instrumentation. Applications with higher reliability requirements may undergo extended burn-in testing or additional verification steps.
All test results are recorded and retained to support batch traceability, customer documentation, and regulatory audits. Units are released for packaging and shipment only after successfully passing all required inspections and tests.
Advanced Manufacturing Capabilities
Altran supports projects ranging from early-stage prototypes to high-volume production programs. Our manufacturing floor is equipped with computer-controlled, automatic winding machines that can maintain tight tolerances and ensure repeatable quality. Shuttle-type winders are used for toroidal products, heavy-duty equipment supports large-gauge conductors, and specialized machinery is dedicated to switch-mode and high-frequency magnetic components.
Our production equipment and processes have evolved in tandem with advancements in magnetic materials and design methodologies. This investment enables Altran to deliver consistent, high-quality magnetics solutions that meet modern performance, reliability, and compliance requirements across a wide range of industries.