An inductor coil on a power electronics PCB.

Power Electronics Design Services

We create power conversion, charging, motor control, and energy storage systems tailored to each product’s electrical, thermal, and operating requirements. Our custom power electronics design covers the process from early concept and circuit development to prototype validation and preparation for production. Throughout the project, we consider efficiency, component selection, thermal performance, manufacturability, protection, and expected operating conditions.

GET IN TOUCH

What we do

We provide custom power electronics design for systems that require efficient conversion, precise control, and reliable operation under demanding conditions. We analyze electrical and thermal requirements, select suitable silicon, SiC, or GaN power devices, and develop the circuitry, PCB, and control firmware around the target operating modes. Simulation and prototype testing verify switching behavior, efficiency, thermal margins, and potential EMI issues before the design is finalized, reducing the risk of failures and costly board revisions.

Battery Energy Storage Systems (BESS)

We start BESS design with the required load profile, storage capacity, operating environment, and power demand. We integrate battery modules, BMS, power converters, sensors, EMS, and thermal management into a coordinated system for controlled energy storage and delivery. This architecture can provide peak shaving, backup power, and reactive power support while making effective use of the available battery capacity.

Battery Management Systems (BMS)

We provide battery management system design for battery packs that require dependable monitoring and fault response throughout their operating life. Our engineers measure cell voltage, temperature, and pack current, implement active or passive balancing, and develop SoC and SoH estimation algorithms. Hardware protection responds to short circuits and abnormal electrical or thermal conditions, helping prevent battery damage and improve pack reliability.

Firmware and Control Software for Power Electronics

We develop real-time control firmware alongside the power hardware so both operate as one coordinated system. As part of our power electronics development, we implement PWM control, synchronized ADC sampling, closed-loop regulation, fault-state management, and industrial communication protocols. Accounting for switching behavior, sensing circuitry, and power-stage dynamics helps improve transient response and regulation accuracy while reducing debugging effort during system integration.

Hardware and PCB Design for Power Electronics

We develop power electronics hardware from system architecture and schematics to PCB layout, prototyping, and validation. Our work includes power electronics PCB design, component selection, thermal implementation, EMI/EMC optimization, and custom magnetics such as high-frequency transformers and inductors. Careful layout and component placement help control parasitic effects, heat, and switching noise while making the design practical to manufacture at volume.

Charging Systems

We design battery chargers and controllers for applications ranging from portable electronics to high-power EV stations. Voltage and current limits, control logic, and configurable profiles are tailored to the battery chemistry and system requirements. Our EV charging system design addresses power conversion, electrical protection, thermal performance, safety, and EMC requirements before production.

Motor Controller Development

We create controllers for brushed DC, BLDC, stepper, and AC motors used in robotics, industrial automation, pumps, fans, and positioning equipment. Our custom power electronics design combines the power stage, feedback circuitry, firmware, and motor-control algorithms around the required motion profile. This allows the drive to provide smooth startup, controlled acceleration, and consistent speed, torque, or positioning across the intended operating range.

Power Conversion Systems

Industrial and specialized equipment often requires power conversion tailored to its load, input source, available space, and operating environment. We engineer AC/DC and DC/DC converters, voltage regulators, and multiphase power stages, with power factor correction where required for AC-powered equipment. Topology, switching devices, magnetics, and control are selected to achieve the required efficiency and regulation while preparing the converter for integration and compliance testing.

Protection and Safety Circuits

Voltage spikes, short circuits, and other electrical faults can damage sensitive components in milliseconds. We design fast hardware protection circuits, surge and overvoltage protection, and galvanic isolation to limit fault propagation and support safe system operation. Our power electronics circuit design helps improve fault tolerance in electrically noisy environments and supports compliance with applicable electrical safety requirements.

What You Get

Hardware Design Documentation

We provide schematics, PCB layouts, 3D models, BOMs, and component data. Your team can use these design files to manufacture the product, maintain it, or make future modifications.

Firmware and Control Software

We deliver source code, binaries, build scripts, and configuration files for embedded control and power management. Your engineers can build, update, and maintain the software independently.

Tested Prototype

You receive assembled and tested prototypes for design validation. We verify electrical performance, conversion efficiency, thermal performance, applicable protection functions, and operation under specified load conditions.

Intellectual Property Rights

You receive ownership of the custom hardware designs, source code, and engineering documentation developed for your project. This gives your team the freedom to manufacture, modify, and further develop the product independently.

Have Your Questions Answered!

Send your requirements and get an assessment

Ask a question

Our projects

Check Integra’s previous projects delivered within our power engineering services.

Battery Management System Development

Integra Sources reviewed the hardware and software of the battery management system. We provided PCB, firmware, app, and server development.

Custom software development
Embedded hardware development
Embedded software development
Firmware development
Web development

SEE THE PROJECT READ THE REVIEW

DC Motor Controller Design

A multi-mode motor controller for robots. Its functions include start and stop, speed regulation, differential steering, and smooth acceleration.

Hardware development
Motor controller

SEE THE PROJECT

Autonomous Robotic Lawn Mower

The robot has an autonomous navigation system with sensors and intelligent algorithms. We provided both hardware design to software development.

Computer vision
Consumer electronics
Embedded hardware development
Embedded software development
Firmware development
R&D
Robotics

SEE THE PROJECT READ THE REVIEW

See All Our Projects

Reviews

"Integra Sources' extensive preparation beforehand helped give confidence to the client that they chose the right partner. Despite the time difference, they are able to stay in constant communication. Integra's dedication to the project has led the client to develop an ongoing relationship."

Christophe Baudia

CEO at GeoMoby

"The database has satisfied all scope requirements. The upgrades have improved communication and performance. Team strengths include accessibility and problem-solving and they are unafraid to research problems and develop their own solutions. Integra demonstrated strong management skills when they managed our servers for a week during an important trade show; we showcased our product at the event. Communication channels are always fluid and straightforward."

Eduardo Ruiz

Founder & CEO at Ruiz Aerospace Manufacturing

"Integra's team helped us clarify our requirements and change systems architecture to achieve the final goal. I'd say that the flexibility and enthusiasm of both engineering and management teams throughout the whole project were some of the things we value most in our collaboration."

Dr. Sam Wass

University of East London

Awards

Frequently Asked Questions

Read this information to better understand the process of power electronics design.

Can you take over a power electronics project that another team started or left incomplete?

Yes. We can take over power electronics development at any stage, from an early prototype to a partially completed design. We start with a technical audit of the schematics, PCB layout, firmware, BOM, and available documentation to identify problems and determine what can be reused. We then complete the remaining work or redesign areas that need correction and validate the updated system through testing. If needed, we can also prepare the product for certification and manufacturing.

How do you protect power electronics from overcurrent, overvoltage, and short-circuit conditions?

Our power electronics services combine fast hardware protection with firmware-based monitoring and fault handling. Depending on the application, we use current sensing and limiting, fuses, TVS diodes or active clamping, comparators, and gate-driver protection such as DESAT. Firmware monitors voltage, current, and temperature and initiates controlled shutdown when required. We set protection thresholds and response times based on the circuit topology, power devices, and operating conditions.

Do you design power electronics for renewable energy or solar applications?

Yes. We develop custom power electronic solutions for solar and other renewable energy systems. Our engineers design DC/DC converters, inverters, battery energy storage systems, BMS hardware, and control firmware. For solar applications, we can implement MPPT control, power conversion and regulation, battery charging, protection functions, and system monitoring. We develop the power stage and embedded control around your voltage, power, efficiency, thermal, and interface requirements.

Can you help reduce EMI to meet EMC compliance standards?

Yes. As a power electronics design company, we reduce conducted and radiated EMI through PCB layout, grounding and return-path design, filtering, shielding, component selection, and switching-edge optimization. We can perform EMC pre-compliance testing, identify EMI sources, and refine the design before formal testing. For U.S. products subject to FCC rules, we account for applicable 47 CFR Part 15 requirements. For the EU, we design to meet the EMC Directive 2014/30/EU and applicable harmonized EN standards based on the product type and intended environment.

What types of power supplies do you design?

We design custom AC/DC power supplies, high-efficiency DC/DC converters, linear and switch-mode power supplies, and Power over Ethernet (PoE) power circuits. Our designs can use isolated or non-isolated topologies depending on voltage, power, safety, and system requirements.

We also develop redundant power architectures with hot-swap support for high-availability systems. As a full-service power electronics outsourcing partner, we design power stages, control circuitry, and embedded control algorithms to optimize efficiency, thermal performance, and footprint for the target application.

What types of batteries do you work with?

We work with a range of rechargeable battery technologies, including Li-ion, Li-polymer (LiPo), LiFePO4 (LFP), NiMH, NiCd, and lead-acid. We select or validate the battery technology and cell configuration based on voltage, capacity, power requirements, cycle life, operating temperature, and safety requirements. Our battery management system design services cover monitoring, protection, cell balancing, state estimation, and charge management for single- and multi-cell battery packs.

What are the main challenges of power electronics development?

The main challenges are managing power losses and heat, controlling EMI, and maintaining stable operation across the full input voltage and load range. We address these issues through component selection, PCB layout, thermal design, filtering, and protection circuitry. We also consider switching transients, parasitic effects, isolation requirements, and EMC requirements early in development to improve reliability and reduce redesigns during validation and compliance testing.

How do you test power electronics?

We start with schematic and PCB layout reviews and circuit simulation, then validate prototypes on the bench. Depending on the device, we measure efficiency, output regulation, ripple, transient response, switching waveforms, and thermal performance across the specified input voltage and load ranges. We also verify startup, shutdown, and protection functions. When required, we perform EMC pre-compliance testing against the standards applicable to the product.