Custom Transformers Designed The Way You Need Them

Custom made transforms are uniquely designed to relevant dimensions, physical constraints, and terminations. Therefore, they offer more effective solutions than a standard transformer that may not fit well. Being an industry-leading custom transformer manufacturer, Custom Coils has been providing high-quality custom transformers and inductors for various challenging client applications, since 1967. Our expertise across a vast range of industries coupled with a well-equipped facility featuring various advanced custom transformer winding equipment enables us quality and fastest turnaround times in the industry. The specialty transformers and inductors provided by us can easily overcome concerns such as complex input and output requirements, multiple operating frequencies, differing impedance levels, and more.

Power Transformers


At Custom Coils, our team of engineers work closely with clients to understand their various mechanical and electrical requirements. A custom transformer design begin with a comprehensive analysis of the client needs and ends with the best possible configurations of core materials, conductors, and specifics.

Why a Custom Transformer

Off-the-shelf devices are typically designed and sized to meet very broad market requirements, which often does not match your needs. These unneeded requirements can make the transformer design too costly and too large. Often times coming up short on other specifications can cause unacceptable performance, higher than normal operating temperatures, and reduced transformer life.

In designing custom magnetics, custom transformers are sought out for various reasons such as:

  • Unusual power requirements.
  • Lack of board or chassis space.
  • Extra features such as different voltage taps or outputs.
  • Ambient temperature range and/or ventilation.
  • Unusual form factors or custom mounting requirements.
  • Specific interfaces: including connectors, terminals, and custom leads.

Unlock More Possibilities with a Custom Transformer

In the ever-evolving landscape of technology, innovation is the key to staying ahead of the curve. Whether you're a forward-thinking business leader, an ambitious entrepreneur, or an avid tech enthusiast, a custom transformer could be the catalyst that propels you towards unprecedented success. Off-the-shelf solutions can only take you so far. A custom transformer is designed to address your specific needs, no matter how unique or complex they may be. With a custom transformer, you're not just buying a part; you're investing in a tailored solution that aligns perfectly with your specifications. Innovation thrives on customization. A custom transformer empowers you to push boundaries, explore uncharted territories, and turn your boldest ideas into reality. With the ability to fine-tune certain aspects of the design specification, you can enhance performance, optimize efficiency, and craft a transformer that meets all your design’s needs.

Precision Engineering for your Unique Needs

As mentioned before, off-the-shelf transformers offer a one-size-fits-all solution, but they can't cater to your exact requirements. A custom transformer, on the other hand, is meticulously engineered to align with your specific needs. Whether you require a transformer for a niche industry, specialized equipment, or unique power demands, a custom solution ensures your design operates at peak efficiency. Also, a custom transformer is designed with your application in mind, optimizing efficiency and performance. By tailoring the design to match your power requirements, load conditions, and voltage levels, you can achieve unparalleled efficiency gains. This not only reduces energy consumption but also extends the lifespan of your equipment, saving you both time and money in the long run.

Custom Design Confidence

When buying off-the-shelf transformers, you must verify the manufacturer’s ratings and standards. If you buy custom magnetics from Custom Coils, your engineering and design teams will be a key factor in the process defining these parameters. They will help define how the part will be used, what the operating environment will be and what specifications will be critical. Once the design is complete, a sample set can be manufactured and tested at your facility in the actual application. It’s only after your testing and approval that the design is considered complete and ready for production.

Custom Transformer and Inductor Solutions We Provide

Being a leading custom transformer and inductor manufacturer, we specialize in the design and manufacturing of the following transformers and inductors:

Custom Transformer Design Features and Specifications

Custom Coils is well-recognized for its reliable, high-quality custom made transformers. Our experts customize or modify any of the transformers in the following specifications:


  • Output Voltage: Up to 60KV
  • Output Power: Up to 2000VA
  • PC Mountable: through-hole or Surface mount
  • Low profile
  • Split Section
  • Encapsulated
  • Flying Leads
  • Custom Choke Designs
  • Bobbin or Coil form


  • Air Coil or Self Support
  • Large or small inductance values (Milliamperes to 10,000 Amps)
  • High current
  • PC Mountable through-hole or surface mount
  • Axial lead or drum core

Overall Capabilities

  • Power Types: Single Phase, Two Phase, Three Phase, and Multi Phase
  • Operating Temperatures: -55 °C to +220 °C
  • Voltage Classes: 600 V, 5kV, 15 kV, and 34.5 kV
  • Insulation Thermal Rating: Up to 150°C
  • Production Volumes: Prototypes, High Volume, and Low Volume
  • Testing and Inspection: At Custom Coils, we conduct 100% testing of our inductors and transformers on the basis of the following parameters:
    • Current
    • Voltage
    • Vars
    • Watts
    • Power Factor
    • VA
    • Efficiency

Design Elements

At Custom Coils, we carefully consider the client requirements while designing and manufacturing custom transformers for their applications. It doesn’t matter, whether you are looking for size, cost, packaging, or electrical performance of your equipment, we can easily fulfill all these requirements.

  • Conductor Materials: Aluminum, copper, foil, and America-made magnet wire
  • Core Materials: Powdered iron alloys, ferrite, mpp, high flux, amorphous, laminated and tape wound
  • Conductor Geometries: Litz wire, round magnet wire, foil, rectangular magnet wire, planar, square magnet wire, stamped windings, and more.
  • Enclosure Types and Options: Non-ventilated, stainless steel, totally sealed, indoor, outdoor, rain shields, and more.
  • Construction: Encapsulated, standard dry type, and cast coil
  • Terminations: SMD, through-hole, flying lead, press fit
  • Vacuum varnish and potted impregnated
  • Soldering, assembly, automated winding
  • Special epoxies, magnetic wires, insulation materials and tapes are used in transformers that have typical flammability and temperature requirements


Our custom made transformers provide the reliability, quality, and efficiency that most industrial applications require. Whether your application demands a space-saving transformer or a reliable solution for a power generation application, we offer performance-driven custom transformer designs that would fulfil your needs.

Industries Served

Over the years, we have established a long list of happy and repeat customers in the following industries with our innovative custom transformer/inductor designs.

Would you like to know more about the possibilities of customizing your transformer designs? You can contact us today to discuss the requirements with our experts. With a vast industry experience to their credit, our experts will guide you in every phase of custom transformer design right from the conceptualization to the final phase of delivery. You can also request a quote, as well as get answers for all your queries at the same time.

Have a question about a custom transformer or any other custom magnetic assembly?

Ask our skilled experts can solve all your queries!

Contact Us At 605.934.2460


Custom Coils
PO Box 348
109 Iowa Street
Alcester, SD 57001-0348

Phone No: 605.934.2460
Fax: 605.934.2440

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