Custom Inductors & Chokes
Engineered precisely around your operating conditions, thermal limits, and saturation requirements. Unlike manufacturers offering only standard off-the-shelf components, Toroid Corporation develops 100% custom-tailored solutions.
Toroid Corporation
Custom Inductor Design
Engineered to Your Specs:
Custom Design Considerations
Our engineering team evaluates the following requirements when developing a custom inductor tailored to your application:
Inductance & Tolerance
Target nominal inductance values and strictly maintained tolerance thresholds across varying operational frequencies.
Current & DC Bias
Continuous rated current, peak surge handling, and DC bias magnetization to prevent magnetic saturation under maximum load.
Frequency & Ripple
Optimized for your specific operating frequency and expected AC ripple current to eliminate audible noise and excess core heat.
Core Selection & Materials
Magnetic materials (iron powder, sendust, ferrite, nanocrystalline, or high-grade electrical steel) selected strictly for application efficiency.
Thermal Performance
Engineered operating temperatures, convection vs. forced-air cooling, and insulation systems rated for Class B (130°C), Class F (150°C), or Class H (180°C).
Physical Configuration
Custom envelope dimensions, PCB pin layouts, flying leads, center-hole potted encapsulation, or custom vertical mounting brackets.
Electrical Performance & Losses
Minimized DC resistance (DCR), controlled AC resistance, low winding capacitance, and tightly targeted copper vs. core loss tradeoffs.
40+ Years of Precision Magnetic Design
Our experienced design group uses sophisticated software programs refined over 20+ years to calculate the optimal and conservative solution for your custom inductor and transformer needs. This eliminates the “human factor” and trial-and-error, ensuring your prototype meets specifications the first time around.
Efficiency Curves
Toroidal core geometry eliminates air gaps in the magnetic path, resulting in virtually zero leakage flux and significantly higher efficiency across nominal load levels.
Thermal Time Constant
A more compact inductor can be engineered when the duty cycle is intermittent and shorter than the thermal time constant of the unit, saving volume and weight.
Operating Temperature Rise
Operating temperature is calculated precisely based on mounting and cooling conditions. Units can be built to UL recognized standards for Class B, E, F, or H.
Voltage Drop Characteristics
Predictable voltage drop characteristics with minimal harmonic distortion across 50/60 Hz and high-frequency operating conditions.
Winding Configurations
Multi-winding arrangements allow series or parallel configurations, custom differential inductances, and balanced multi-rail filtering.
Rectifier Filter Inductors
Our design software accurately calculates ripple suppression and DC bias tolerances specifically for full-wave and bridge rectifier filtering circuits.
Custom Inductor & Choke Applications
Custom inductors and chokes may be designed for applications including:
Power Supplies & Power Conversion
High-efficiency filter inductors, boost/buck PFC chokes, and energy storage chokes for SMPS and DC-DC converters.
Industrial Equipment & Controls
Rugged magnetic chokes engineered for motor drives, robotics, automation systems, and variable frequency drives (VFDs).
Electrical Noise Filtering
Common-mode and differential-mode toroidal filtering inductors for critical EMI/RFI suppression in sensitive electronics.
Renewable Energy & Power Systems
Grid-tie solar inverters, battery storage conversion, wind generators, and power factor correction magnetics.
Medical & Electronic Equipment
Low-leakage, high-dielectric inductors designed for medical diagnostics, surgical instrumentation, and laboratory devices.
Specialized OEM Applications
Custom-configured inductors built to proprietary OEM mechanical and electrical blueprints with guaranteed repeatability.
Talk to a magnetics designer. Not a sales rep.
Whether you need custom toroidal inductors, common-mode chokes, or high-frequency filter assemblies, our engineering team reviews your specifications directly. Detailed design proposals typically turn around within 48 hours.
