Overview
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. 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 produ