Fully customizable workflow

1. Features of the Full Custom Workflow

Full custom is a custom solution in which the circuit, transformer, PCB, and enclosure are newly designed from scratch. We create a completely made-to-order power supply tailored to your requirements, including unique specifications not achievable with standard products, integrated device structures, and compliance with special operating environments.

The full custom workflow has the following features.

• Complete compliance with requirements: Dedicated designs are possible that fully match the mechanical constraints, electrical requirements, and operating environment demands of the equipment.
• Support for integrated devices and special shapes: We accommodate structures not achievable with standard products, such as built-in board power supplies, special enclosures, proprietary connectors, and special cables.
• Differentiation through proprietary specifications: By adopting a unique design that competitors cannot easily replicate, it leads to a competitive advantage for your final Products.
• New acquisition of international safety certifications: We newly obtain safety certifications according to the destination country, such as PSE, UL, CE, GS, CCC, and KC.
• Design based on long-term supply: By designing with consideration for continuous component procurement and mass production stability, we support stable long-term supply.

Difference from semi-custom: Semi-custom involves modifying certain specifications based on our standard products and does not require a new design process. Full custom, on the other hand, involves entirely new development from market analysis to basic design, detailed design, prototyping, certification acquisition, and mass production. Although development time and cost increase, complete compliance with requirements is possible. If your needs can be met with a standard product base, please also refer to the semi-custom workflow page.

2. Overall Workflow

Full custom development proceeds through the following 8 steps. We provide consistent support from initial inquiries and new design to certification acquisition, mass production launch, and ongoing supply thereafter.

3. Details of Each Process

We will introduce what is carried out in each process and what kind of information exchange occurs.

STEP 1: Inquiry and Requirements Hearing

We conduct a hearing of your requirements through the inquiry form or our sales representatives. In the case of full custom development, thoroughly confirming the mechanical constraints and electrical requirements on the equipment side is directly linked to the design quality in subsequent processes.

• Equipment application, assumed usage methods
• Required output specifications (voltage, current, multiple outputs, USB PD profile, etc.)
• Mechanical requirements (housing size, installation method, integrated with equipment/standalone type)
• Operating environment (ambient temperature range, humidity, outdoor installation, vibration, salt damage, lightning surge, etc.)
• Destination country and sales market (to determine required safety certifications)
• Expected production volume, mass production start timing, long-term supply period
• Unique requirements (special shapes, special connectors, branding, communication functions with equipment, etc.)

If you can provide equipment drawings, specifications, samples of competing products, etc., subsequent consideration will proceed smoothly. We also support detailed discussions after concluding an NDA.

STEP 2: Proposal of Basic Design Policy

Based on the information gathered during the hearing, our power supply design department will formulate and propose a basic design policy. At this stage, the following items will be determined.

• Selection of circuit method and topology (flyback, forward, resonant, etc.)
• Policy for selecting major components (power devices, transformers, output capacitors, etc.)
• Structural policy (board configuration, thermal design, insulation design)
• EMC and noise countermeasure policy
• Applicable safety standards and certification schedule
• Estimation of development period, development cost, and expected mass production unit price

At this stage, we will present a draft technical specification and conceptual diagrams to the customer, and upon agreement, proceed to the detailed design phase.

STEP 3: Detailed Design

Based on the finalized basic design policy, detailed design of each element will be carried out.

• Circuit design: main circuit, protection circuits, feedback control, inrush current countermeasures, etc.
• Transformer design: winding design, insulation structure, leakage inductance, temperature rise
• PCB design: pattern layout, thermal design, insulation distance, ensuring manufacturability
• Enclosure and mold design: mechanical strength, heat dissipation, assemblability, compatibility with equipment
• EMC/EMI design: noise filters, shielding, ground design
• Finalization of component selection: considering component availability and long-term supply stability

At each stage of the detailed design process, design reviews will be conducted to verify quality and compliance with specifications.

STEP 4: Prototyping and Customer Evaluation

Based on the detailed design, a prototype unit is manufactured. For the enclosure, prior to production using the final mold, prototyping may be carried out using methods such as a simplified mold or 3D printing.

We conduct electrical characteristic evaluation, temperature testing, and reliability evaluation, and provide the evaluation data to the customer. The customer will also conduct combination testing with the actual equipment and operational verification.

If design revisions are required based on the evaluation results, we will respond with redesign and re-prototyping. The design is finalized once this prototype evaluation is completed.

STEP 5: Acquisition of Safety Certifications

After the design is finalized, we obtain new safety certifications required for the destination countries. In the case of a full custom design, certification must be obtained from scratch, and certification is issued after testing and review at an authorized laboratory.

The main safety certifications we can support are as follows.

• Japan: PSE
• North America: UL, cUL, FCC
• Europe: CE, GS, UKCA
• China: CCC
• Korea: KC
• Taiwan: BSMI
• India: BIS
• Oceania: RCM
• Others: Individual support depending on the destination country

Obtaining certification takes approximately 1 to 6 months depending on the destination country. In accordance with the project schedule, we prioritize obtaining the required certifications.

STEP 6: Pilot Production (Pilot Run)

After preparing the production molds, jigs, and inspection equipment, a pilot run is conducted at the mass production factory. This is the final verification process before mass production begins, and the following items are evaluated.

• Assembly and workability in the mass production process
• Variation in electrical characteristics of mass-produced products
• Validity of the inspection process
• Quality stability of the initial lot
• Estimated lead time and yield rate

Pilot run samples are also provided to customers to obtain final approval before starting mass production.

STEP 7: Mass Production and Quality Inspection

Production begins at the mass production factory. For mass-produced products, we implement the following three stages of quality inspection.

• Incoming Quality Control (IQC): All components except certain packaged parts are subject to sampling-based incoming inspections and hazardous substance testing.
• In-Process Quality Control (IPQC): For all lots, we verify production in accordance with specifications, proper ultrasonic welding, and process progress based on work instructions.
  In addition, for semi-Products and finished products, insulation resistance tests and dielectric withstand voltage tests are conducted for all production lots to ensure quality.
• Outgoing Quality Control (OQC): Electrical characteristics based on safety standard requirements and specifications are inspected by sampling for all production lots.

For inspection standards, we adopt ANSI/ASQ standard Z1.4 Level-II, and AQL criteria are established for critical defects, major defects, and minor defects. For more details, please refer to the Our Quality Initiatives page.

STEP 8: Continuous Supply and After-Sales Service

After mass production begins, we support long-term continuous supply and after-sales service. Since full custom products are exclusively designed, it is also an advantage that long-term supply strategies can be easily planned in accordance with the customer's business plan.

• Traceability Management: We store production history data for 20 years, enabling long-term quality tracking.
• Defect Handling: In the event of a defect, we conduct analysis, identify the root cause and outflow cause, and implement measures to prevent recurrence.
• Support for Derivative Products and Additional Specifications: Even after mass production begins, we flexibly respond to derivative products with different cables and additional specifications for other destinations.
• Component EOL Management: If production discontinuation (EOL) of used components occurs, we evaluate switching to alternative components and handle re-certification to maintain long-term supply.
• Long-Term Supply: We monitor component procurement conditions to support stable long-term supply.

4. Contact

For full custom solutions, we provide comprehensive support from requirement hearings and basic design proposals to detailed design, certification acquisition, and mass production. If you have projects such as "requirements that cannot be met by standard products," "considering an integrated power supply for equipment," or "wanting to differentiate from competitors with unique specifications," please feel free to contact us.

Contact Us About Full Custom Solutions

Request the General Products Catalog