What is custom power supply support?

As electronic devices become more advanced, compact, and diversified, there are increasing cases where general-purpose standard AC/DC Power Adapter and switching power supplies cannot meet requirements. Needs on the device side are becoming more segmented each year, including miniaturization through the adoption of GaN (gallium nitride), specialized requirements for medical, industrial, and IoT equipment, and compliance with safety standards in various countries. The solution to meeting these "requirements that standard products cannot satisfy" is custom power supply support. However, although it is collectively referred to as "custom," there are למעשה two major approaches: full custom and semi-custom (modify), each differing in suitable applications, cost, and delivery time. This article explains, for BtoB design and procurement professionals responsible for selecting AC/DC Power Adapter and switching power supplies, the overall picture of custom solutions, the differences between full custom and semi-custom, the criteria for choosing between them, and the features of our company's support.

1. What Is Power Supply Customization?

Power supply customization refers to adjusting specifications to match a customer's equipment, application, and market, or designing a new product from scratch, rather than adopting a standard mass-produced model as-is.

AC/DC Power Adapter and switching power supplies may appear simple, but they are Products with numerous design elements, including output characteristics, protection circuits, noise performance, insulation structure, safety standards, mechanical shape, and cable and connector specifications. As equipment becomes more advanced, if even one of these elements does not match a standard product, customization needs to be considered.

Main Reasons Customization Is Chosen

The following circumstances often lead customers to consult us about customization.

Output specifications not available in standard products: Required voltage and current combinations, special USB PD profiles, multiple outputs, etc.
Does not fit the equipment's shape or mounting requirements: Enclosure size, connector shape, cable length, locking mechanisms, etc.
Country-specific safety standards and plug shapes are required: Japan PSE, North America UL, Europe CE/GS, China CCC, Korea KC, etc.
Branding requirements: Differentiation elements such as nameplates, engravings, colors, and logos
Special operating environments: Wide temperature range, waterproofing, outdoor installation, vibration, lightning surge environments, etc.
Replacement of existing products: PSE non-compliance of overseas adapters, discontinued products, etc.

Three Approaches to Custom Support

We use the following three approaches depending on customer requirements and project scale.

Approach	Overview
Modified Custom	The lightest approach, involving changes only to certain specifications of standard products (such as cables, connectors, and nameplates).
Semi-Custom	Based on standard products while adjusting electrical specifications such as output characteristics and protection circuits.
Full Custom	Designed from scratch, including circuits, boards, transformers, and enclosures. Full compliance with requirements is possible.

In this article, we will focus on two approaches frequently inquired about in practice - Semi-Custom (including Modified Custom) and Full Custom - and explain their respective features in order.

2. What Is Semi-Custom (Modified Custom)?

Semi-custom is a method in which some specifications are modified based on our existing standard products to meet customer requirements. Since it does not involve new design development, it enables compliance with requirements while significantly reducing development time and cost.

Examples of Modifiable Items

Output cable length and connector type
Input plug replacement (U/E/A/UK, etc. by destination country)
Adjustment of output voltage and current
Optimization of overcurrent protection (OCP) characteristics
Extended lifespan support by changing electrolytic capacitor specifications
Nameplate, marking, and logo printing
Moisture-proof coating and flame-retardant grade changes
Packaging specifications and accessory configuration changes

Regarding extended lifespan support: For all Products, we can consider adjusting the Products lifespan by changing the specifications of electrolytic capacitors according to the customer's operating conditions. For example, in response to a requirement such as "10-year lifespan under conditions of 24-hour operation at 70% of rated load and an ambient temperature of 40°C," we will individually evaluate whether adjustments are possible within the capabilities of the applicable model. We receive many inquiries for applications that assume long-term operation, such as industrial equipment, telecommunications devices, and unmanned systems.

Advantages of Semi-Custom

Semi-custom offers the following advantages that full custom does not.

Short lead time: Since it is based on standard products, the new design process can be omitted. Depending on the specifications, delivery is possible in as little as a few weeks~a few months.
Lower cost: As there is no need for new mold production or circuit design costs, initial expenses can be significantly reduced.
Limited re-certification scope: Existing safety certifications obtained for the base model can be utilized, and in many cases, only differential certification for modified parts is required.
Suitable for small~medium lots: Without mold investment, projects with small to medium production volumes are more likely to be cost-effective.
Proven circuit designs can be reused: Since designs with mass production track records are used as a base, stable quality can be expected.

Key point: Before proceeding with new development, our basic approach is to first propose whether the issue can be resolved through semi-customization of a base model. In many cases, projects initially considered to require "full custom" can be sufficiently achieved with semi-custom solutions.

Cases Where Semi-Custom Is Suitable

Projects that can be handled with standard specifications + alpha (different plug, different cable, different nameplate, etc.)
Projects that prioritize delivery time, or where mass production schedules are tight
Projects with lot sizes of several hundred to several thousand units
Replacement of existing products where you do not want to change the equipment specifications
Projects that aim to enter the market while keeping initial costs low

Reference Examples

Please also refer to the following pages for examples where challenges were actually solved through semi-custom solutions.

3. What Is Full Custom?

Full custom is a method in which the circuit, PCB, transformer, and enclosure are designed from scratch. Instead of using standard products as a base, the optimal configuration is newly created to meet the customer's requirements, offering an exceptionally high degree of flexibility.

Scope of Full Custom Support

Circuit design (topology selection, protection circuit design, control method optimization)
Transformer design (winding design, leakage inductance, insulation structure)
PCB design, component layout, thermal design
Enclosure design, mold fabrication, mechanical design assuming integration into equipment
EMC countermeasures, noise filter design
New acquisition of international safety certifications (PSE, UL, CE, GS, CCC, KC, BIS, NOM, etc.)

Advantages of Full Customization

Complete compliance with requirements: All constraints and required specifications on the equipment side can be fully accommodated.
Support for integrated equipment and special shapes: Compatible with built-in board power supplies, special enclosures, proprietary connectors, etc.
Differentiation through proprietary specifications: By adopting a unique design that is difficult for competitors to imitate, it leads to a competitive advantage for the Products.
Long-term supply stability: As it is an in-house design, it becomes easier to establish long-term plans including component supply strategies.
Cost optimization: For projects with large mass production volumes, a dedicated design may be more advantageous in terms of total cost.

Considerations for Full Customization

Development period: From finalizing specifications to mass production, it is necessary to expect about 6 months~1 year or more.
Initial costs: Development costs, tooling costs, and certification acquisition costs will be incurred.
MOQ (Minimum Order Quantity): From the perspective of investment recovery, a certain level of mass production volume is assumed.
Timing of specification freeze: Major specification changes during development will affect schedule and cost. Early finalization of specifications is important.

Cases Where Full Custom Is Suitable

Projects that require a unique power supply specification that cannot be achieved with standard products
Projects that require integration into equipment, special enclosures, or special shapes
Projects where mass production of several thousand units or more per year is expected
Projects with strict environmental performance requirements (wide temperature range, waterproofing, vibration resistance, lightning surge resistance, etc.)
Projects where long-term supply and stable quality are critical to the business

Reference Case Studies

Please also refer to the following pages for examples achieved through full custom solutions.

4. Comparison Between Semi-Custom and Full Custom

Semi-custom and full custom differ significantly in scope, cost, delivery time, and suitable project scale. Please use the comparison table below as a reference when making your selection.

Comparison Item	Semi-Custom	Full Custom
Development Period	Short (a few weeks to several months)	Long (6 months to over 1 year)
Initial Cost	Can be kept low	Development and mold costs required
Minimum Order Quantity	Small to medium lots available	Suitable for medium to large lots
Design Flexibility	Within the scope of the base model	Almost unlimited
Safety Certification	Often covered by certification of differences	New certification required
Built-in Equipment Support	Within standard form factors	Supports integrated equipment design
Suitable Projects	General specifications + α, delivery time priority	Unique specifications, special shapes, mass production

Decision Criteria: The choice between semi-custom and full custom is determined by the balance of design flexibility x lot size x delivery time. Whether all requirements truly need to be achieved through full custom can be better assessed by consulting with us at the initial stage to identify the most appropriate approach.

5. Custom Solutions by Industry

We have extensive experience providing custom power supplies across a wide range of industries, including home appliances, medical, industrial, telecommunications, and IoT. The requirements vary significantly by industry, and industry-specific expertise greatly influences design precision.

For Home Appliances

In home appliance Products, a balance of cost, size, and safety is emphasized. Safety design for household use, support for long operating hours, and compliance with standby power regulations are required. For more details, please refer to the case study of AC/DC Power Adapter for home appliances.

For Medical Devices

For medical devices, compliance with stringent medical safety standards such as IEC 60601-1 is essential to ensure the safety of patients and operators. Leakage current control, insulation structure, and reliability testing are all required to meet medical-grade standards. For more details, please refer to the case study of AC/DC Power Adapter for medical devices.

For Information Technology Equipment

For telecommunications equipment, server peripherals, and office automation equipment, continuous long-hour operation, thermal design, and EMC measures are critical. We also support the latest standards, including USB Power Delivery. For more details, please refer to the case study of AC/DC Power Adapter for information technology equipment.

For Industrial Equipment

In FA equipment, measuring instruments, and control devices, reliability in harsh environments is required, including wide temperature ranges, dust and water resistance, vibration resistance, and long service life. For details, please refer to the case studies of AC adapters for industrial equipment.

For Electronic Musical Instruments, Audio, and Video Equipment

In audio equipment, noise characteristics directly affect sound quality, so low ripple and low noise design are emphasized. Stable power supply is also essential for maintaining image quality in video equipment. For details, please refer to the case studies of AC adapters for electronic musical instruments, audio, and video equipment.

For Smart Meters and HEMS

Smart meters and HEMS devices require long-term continuous operation, low power consumption, and wide temperature and weather-resistant design for outdoor installation. For details, please refer to the case studies of AC adapters for smart meters and HEMS.

For IoT/M2M Devices

For IoT devices, miniaturization, low power consumption, and simultaneous compliance with international standards are common challenges, and connector and cable requirements on the device side are becoming increasingly diverse. For details, please refer to the case studies of AC adapters for IoT/M2M devices.

View the list of custom case studies

6. Strengths of Our Custom Support

Since our founding in 1989, we have specialized exclusively in AC/DC Power Adapter and switching power supplies for over 35 years. In addition to selling standard products, we have positioned customer-specific customization as a core business, developing the following strengths.

Design Expertise as a Dedicated Power Supply Manufacturer for Over 35 Years

Our specialized power supply design department handles everything from circuits, transformers, enclosures, EMC, to safety standards in an integrated manner, enabling us to accumulate cross-industry design expertise. With our motto, "Responding to 'I wish something like this existed...'", we have flexibly addressed requirements that cannot be met by standard products.

Wide Range of Semi-Custom Options Backed by an Extensive Standard Product Lineup

The success of semi-custom solutions largely depends on the breadth of available base standard products. We offer a diverse lineup of standard product series as shown below, allowing us to start from the base model that most closely matches your requirements.

Compact AC/DC Power Adapter equipped with GaN FET
Open-frame switching power supplies
USB PD-compatible AC/DC Power Adapter
Medical AC/DC Power Adapter (IEC 60601-1 compliant)
Wide temperature range AC/DC Power Adapter (-20°C~+60°C)
Waterproof AC/DC Power Adapter
High-wattage type (~300W class)
4-direction interchangeable AC plug AC/DC Power Adapter

Compliant with Global Safety Standards

We have a proven track record of compliance with safety standards in various countries, including Japan's PSE, North America's UL, Europe's CE/GS, China's CCC, Korea's KC, Taiwan's BSMI, India's BIS, and Oceania's RCM. We support certification acquisition according to the destination country on a project-by-project basis.

Robust Quality Control System

We have established a system that supports post-mass-production quality, including supplier selection, PSE compliance verification, reliability testing, and traceability management. Traceability data is stored for 20 years, supporting long-term Products supply and after-sales service. For more details, please refer to our Quality Initiatives page.

Proven Track Record with Major Manufacturers

We have supplied custom power supplies to major manufacturers across a wide range of fields, including telecommunications equipment, office automation equipment, industrial equipment, medical devices, and broadcasting equipment. Our achievements include providing technical cooperation for the production of NHK's "Chico-chan ni Shikarareru!" program and receiving letters of appreciation from our business partners, reflecting the long-standing relationships of trust we have built over the years.

7. Frequently Asked Questions

Q. What is the minimum order quantity (MOQ)?

For semi-custom projects, we may be able to accommodate orders starting from several hundred units depending on the case. For full custom projects, a certain production volume is generally required in order to recover development investment costs. The specific quantity varies depending on the requirements and cost structure, so please contact our sales team first.

Q. What is the estimated development timeline?

Semi-custom projects typically take several weeks to several months, while full custom projects generally take six months to over one year. The timeline varies depending on whether safety certifications are required, the scope of certification, the number of prototypes, and the customer's evaluation period.

Q. Can I consult with you if I only want to change the output voltage or cable of an existing model?

Yes, it is possible. With our modify-custom and semi-custom services, we can accommodate partial specification changes such as adjusting output voltage and current, changing cable length or connectors, and replacing input plugs.

Q. Can you support obtaining overseas safety certifications?

Yes, we can. We support certification acquisition according to the destination country, including Japan's PSE, North America's UL, Europe's CE/GS, China's CCC, Korea's KC, Taiwan's BSMI, India's BIS, and Oceania's RCM.

Q. Can we consult with you about replacing existing products (such as non-PSE-compliant products)?

Yes, we can. We have experience handling replacement projects for existing products, including non-PSE-compliant imported adapters, discontinued products, and switching from overseas manufacturers. If a short lead time is required, we may be able to propose a semi-custom replacement solution.

Q. What if we are unsure whether full custom or semi-custom is more suitable?

After hearing your requirements, we will make a proposal. In general, we first consider whether a semi-custom solution is feasible, and if not, we proceed with a full custom option. Please feel free to contact us even if you are still at the stage of deciding.

8. Summary

There are two approaches to custom power supply solutions: semi-custom (including modifications) based on standard products, and full custom designed from scratch. The most suitable option depends on the balance between specification flexibility, lot size, delivery time, and initial cost.

As a dedicated power supply manufacturer with over 35 years of experience, we leverage our design expertise and extensive standard product lineup to propose the approach best suited to your requirements. Even for projects that may seem to require full custom development, we first consider whether a semi-custom solution can meet your needs, contributing to the optimization of your development time and costs.

If you are facing requirements that cannot be met by standard products, or if you are unsure how far customization can go, please feel free to contact our sales team. We provide careful support from hearing your requirements to proposing the most suitable approach.

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