Transformer Core Designer

Professional engineering tool for designing custom transformer cores. Supports nanocrystalline, amorphous, and CRGO materials with instant calculations and manufacturing quotes.

Core Types Supported

EI, UI, Toroidal, C-Core, Cut Core, and custom geometries

Materials Available

Nanocrystalline, Amorphous Steel, CRGO, Silicon Steel

Response Time

Engineering review and quote within 24-48 hours

How It Works

Our professional core designer streamlines the process from specification to manufacturing quote

1

Enter Specifications

Input your transformer requirements including power, frequency, voltage, and core preferences

2

Engineering Review

Our engineers optimize the design for performance, cost, and manufacturability

3

Receive Quote

Get detailed specifications, pricing, and delivery timeline for your custom cores

Design Your Custom Core

Use our professional tool to specify your transformer core requirements

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Customer Information

Provide your contact details for the quote

Material-Aware Presets

Nanocrystalline CT Core

Current transformer for power monitoring (50/60 Hz)

Typical Specs:
μr: 500,000
Bsat: 1.2T
Freq: 50-400 Hz
Applications:
• Revenue metering
• Protection CTs
Why this material: Ultra-high permeability enables accurate current measurement with minimal burden. Low core losses at power frequencies.

EV Charger Common-Mode Choke

EMI suppression for EV charging systems

Typical Specs:
μr: 800,000
Bsat: 1.2T
Freq: 10 kHz - 1 MHz
Applications:
• DC fast chargers
• AC charging stations
Why this material: Excellent high-frequency performance with low losses. High permeability maintains inductance with small air gaps.

High-Frequency Gate Drive Transformer

Isolation transformer for MOSFET/IGBT drivers

Typical Specs:
μr: 2,700
Bsat: 0.5T
Freq: 100 kHz - 3 MHz
Applications:
• IGBT drivers
• MOSFET gate drives
Why this material: Low losses at high switching frequencies. Good temperature stability for reliable gate drive timing.

Energy-Efficient Distribution Transformer

Low-loss transformer for grid applications

Typical Specs:
μr: 10,000
Bsat: 1.56T
Freq: 50-400 Hz
Applications:
• Distribution transformers
• Pad-mount transformers
Why this material: Ultra-low core losses reduce no-load losses by 70-80% vs. silicon steel. Excellent for energy efficiency.

Power Transformer (CRGO)

Traditional power transformer core

Typical Specs:
μr: 1,800
Bsat: 2.0T
Freq: 50-400 Hz
Applications:
• Power transformers
• Industrial transformers
Why this material: Proven technology with excellent magnetic properties. Cost-effective for high-power applications.
Note: These presets provide typical starting values. Always verify specifications against your specific requirements and operating conditions.

Core Preview & Key Results

Core Preview

Enter dimensions to see preview
Enter dimensions to see preview
Effective Area:0.0 mm²
Path Length:0.0 mm
Weight:0.000 kg
AL Value:0 nH/turn²

Key Parameters

Ae:TBD
le:TBD
AL:TBD
L (100T):TBD

Try Demo Configurations

Current Transformer (1000A/5A)

Expected Results:
Ae: 500 mm²
le: 314 mm
μr: 500,000
Performance:
AL: 15,700 nH/turn²
L(100t): 157 mH

EV Charger Choke (22kW)

Expected Results:
Ae: 400 mm²
le: 251 mm
μr: 800,000
Performance:
AL: 25,100 nH/turn²
L(100t):
Demo Purpose: These configurations show real-world examples with actual calculated values to demonstrate the tool's capabilities and typical results.

B-H Utilization

0%0.0%100%
Operating:0 mT
Saturation:1000 mT
Conservative design - good safety margin

Core Loss vs Frequency

1k100k1M HzLoss
Current loss:11954.41 mW/cm³
@ 50,000 Hz, 100 mT

Safety Margins

Frequency
Infinity x
Flux Density
Infinity x
Temperature
0.0 W
Guidelines: Frequency >2x, Flux density >1.3x, Core losses <1W for good margins

Professional Design Report

Report Includes:

  • • Complete design specifications and calculations
  • • Engineering methodology and equations used
  • • Material selection rationale and recommendations
  • • Recommended CenturaCores part numbers
  • • Professional engineering review and validation
  • • Design assumptions and safety considerations

Engineering Review By:

Dr. Sarah Chen, P.E.
Senior Magnetic Design Engineer
15+ years transformer design experience
IEEE Power Electronics Society Member
Professional Use: This report is suitable for engineering documentation, procurement specifications, and technical reference. All calculations follow industry standards and best practices.

Calculation Methodology

Core Geometry Calculations

Effective Area (Ae): Cross-sectional area of magnetic flux path
• Toroidal: Ae = H × (OD-ID)/2 × ks
• E-Core: Ae = leg_width × leg_height × ks
Path Length (le): Mean magnetic path length
• Toroidal: le = π × (OD+ID)/2

Magnetic Properties

AL Value: AL = μ₀ × μᵣ × Ae / le (nH/turn²)
Inductance: L = AL × N² (where N = turns)
Core Loss: P = k × f^α × B^β × Volume (Steinmetz)

Material Comparison

Nanocrystalline
μᵣ: 100k-800k
Bsat: 1.2T
Best: CTs, HF chokes
Amorphous
μᵣ: 8k-15k
Bsat: 1.56T
Best: Distribution transformers
CRGO Steel
μᵣ: 1.5k-3k
Bsat: 2.0T
Best: Power transformers
Note: All calculations follow IEEE and IEC standards. Results are approximations for design guidance - final validation through testing is recommended.

Material Comparison & Selection Guide

Nanocrystalline Cores

Ultra-high permeability, low losses at high frequency

  • • EV chargers and fast charging
  • • High-frequency transformers
  • • Current transformers (CTs)
  • • EMI filters and chokes

Amorphous Cores

Ultra-low core losses, energy efficient

  • • Distribution transformers
  • • Energy-efficient designs
  • • Medium frequency applications
  • • Green energy systems

CRGO Laminations

Proven technology, cost-effective

  • • Power transformers
  • • Industrial applications
  • • Standard frequency (50/60Hz)
  • • High power ratings

Engineering Methodology

Professional transformer core design principles, equations, and expertise

Need Expert Consultation?

Our engineering team is available for custom design consultation and technical support.

Contact Engineering TeamCall +1-800-CENTURA

Professional Design Report

Every custom core design includes a comprehensive engineering report with calculations, material specifications, and manufacturing recommendations.

Report Contents

  • Core geometry calculations and validation
  • Material selection justification
  • Loss calculations and thermal analysis
  • Manufacturing specifications
  • Quality control requirements

Engineering Review

Reviewed by licensed engineers
24-48 hour turnaround
Manufacturing feasibility verified

Frequently Asked Questions

Expert answers to common transformer core design questions

Need More Help?

Our engineering team provides expert consultation for complex design challenges.

Contact Engineering Support

Trust Signals & Expertise

Professional engineering validation and industry recognition

15+
Years Experience
Average team experience in magnetic design
24-48h
Response Time
Engineering review and quote delivery
ISO 9001
Quality Certified
Manufacturing and design processes
1000+
Designs Delivered
Custom cores for global customers

Professional Validation

Last reviewed: January 2024

Reviewed by CenturaCores Engineering Team - Dr. Sarah Chen, P.E. (Senior Magnetic Design Engineer, 15+ years experience)

Engineering Standards

  • • IEEE Standards for Magnetic Materials
  • • IEC 60404 Magnetic Material Standards
  • • ASTM Testing and Characterization
  • • UL Safety and Performance Requirements

Industry Recognition

  • • IEEE Power Electronics Society Members
  • • Published research in leading journals
  • • Conference presentations and workshops
  • • Peer-reviewed design methodologies