The Magnetic Products Technology Centre is at the forefront of our solution led approach for applications that require customised cores and components, driving our commitment to developing an enhanced technological future together.
Consultancy and custom magnetic solutions for power applications
Magnetic Products Technology Centre
The Magnetic Products Technology Centre supports design and industrialisation of inductive components and soft-magnetic cores for power applications.
We cover the engineering steps from requirements definition and material selection to electromagnetic/thermal design, prototype builds, and validation (testing and inspection).
Our focus is power applications in the frequency range 5–200 kHz and power range 1 W–100 kW, mainly for industrial, medical, renewable energy, and automotive use cases. Typical components include transformers, inductors, chokes (common-mode and differential-mode), coils, and assemblies. We also manage the Acal BFi kOr core line, covering amorphous, nanocrystalline, and ferrite materials.
For series production, we also manage the operational side: production and material coordination, quality assurance, traceability, documentation and change control, , and logistics and warehouse solutions.
Part of the Technology Network
Each Technology Centre is part of Acal BFI’s wider Technology Network, giving you access to a collaborative team of specialist engineers across multiple disciplines. This connected approach allows us to support larger, more complex projects that span multiple technologies – from embedded computing and wireless to power, sensing, photonics, and imaging. By bringing expertise together across our centres, we help reduce design risk, simplify integration, and deliver complete, production-ready solutions through a single, trusted engineering partner.
What we do at the Magnetic products Technology Centre
The Magnetic Products Technology Centre (MagTC) is based at our German site near Frankfurt, with ten dedicated engineers and specialists work exclusively on implementing customised magnetic solutions for clients across Europe.
Every magnetic project begins with a detailed understanding of your technical, environmental, and performance requirements. We then guide you through technology selection, optimisation, and implementation — whether that starts with a standard component, a semi‑custom adaptation, or a fully tailored magnetic design.
Our support covers the full spectrum of services, including:
- Technical consulting and design support
- Define magnetic performance parameters based on real‑world operating conditions
- Select optimal core materials, geometries, and magnetic components
- Prototype production and testing
- Validation of magnetic behaviour and performance with simulation and prototyping
- Supply chain management and quality assurance for series production
- Integrate standard, semi‑custom, or custom magnetic solutions
- Reduce technical risk and accelerate time to production
We focus primarily on power applications in the frequency range 5–200 kHz and power range 1 W–100 kW, serving industries such as industrial automation, medical technology, renewable energy, and automotive. Our team also develops and manufactures magnetic cores for the Acal BFi kOr line, including amorphous, nanocrystalline, and ferrite cores.
By combining deep application knowledge with access to a wide range of magnetic materials and manufacturing expertise, our engineers deliver magnetic solutions optimised for efficiency, size, cost, and reliability — helping your project succeed from concept to production.
Our Technical Capabilities
The Magnetic Products Technology Centre provides a comprehensive set of capabilities, structured into Standard, Semi-Custom, and Custom services. This ensures we can support a spectrum of needs — from selection and integration of existing products to fully bespoke magnetic designs tailored to complex challenges.
What are the key stages in developing a reliable custom magnetic solution from concept to production?
Collaborative expertise across Acal BFI Technology Centres
The Magnetic products Technology Centre works closely with our other Technology Centres to deliver fully integrated system solutions. When your project requires additional specialist support, we collaborate with teams from Wireless & IoT, Power Supply and Sensor & Imaging Centres to provide a seamless, multidisciplinary approach. By combining expertise across embedded platforms, power management, connectivity, sensing, and more, we create tailored solutions that address the complex, evolving challenges of modern electronic design.
Why work with the Magnetic Products Technology Centre?
With our dedicated consulting, engineering, manufacturing, and testing resources, we ensure to find an optimum solution for your requirements.
- Specialised magnetics expertise: Over 25 years of design-led magnetic engineering experience.
- Broad technology coverage: Expertise across power, signal integrity, EMI suppression, and advanced core materials.
- Risk reduction: Simulation, prototyping, and performance verification to validate designs before full production.
- Material and engineering expertise – for demanding applications, including renewable energy, rail, automotive, medical, and automation. We understand the real-world constraints engineers face — from board space and cost pressures to thermal and environmental performance.
- European based collaborative design partnership – our local field sales engineers and the Germany based MagTC team work directly with your engineering team, from material selection to series product approval process.
- Proven track record – We have successfully developed custom magnetics for OEMs across Europe. Our long-term partners rely on us for continuous design refinement and lifecycle support.
Why Acal BFi? Your partner for magnetic product solutions
With decades of experience supporting magnetic products, Acal BFi combines technical expertise with a broad supplier ecosystem to deliver robust, application-matched embedded computing solutions. We provide:
- Collaborative partnership: Working as an extension of your engineering team to solve complex magnetic challenges.
- End-to-end support: From component selection to custom design and production readiness.
- Semi-custom and custom solutions
- Comprehensive in-house capabilities – From design and modelling to prototyping and testing: to-end support under one roof. This reduces development time, ensures consistency, and accelerates time-to-market.
- ISO 9001 certified facilities – Our processes follow strict quality and traceability standards, providing the confidence you need for critical applications.
- Supply chain reliability – We work closely with trusted material manufacturers, technology and logistic partners to ensure consistent availability, even for special components.
Supported by centralised logistics and a pan-European engineering network, we help ensure reliable supply, technical continuity, and confidence throughout your product’s lifecycle.
We offer a broad range of custom magnetic components mainly for power (focus on frequency range 5–200kHz and power range 1W–100kW) and metering applications, including: transformers, inductors and chokes (common mode and differential mode), coils and other assemblies. We also develop magnetic cores for such applications from amorphous, nanocrystalline and ferrite materials.
MagTC is completely independent in its choice of materials and technologies. This allows products to be optimally adapted to specifications, installation conditions, cost frameworks, etc. – provided that the application offers the freedom to do so. The earlier and better degrees of freedom can be utilised, the greater the potential technical and cost advantage over a standard component.
The technical design must be developed in close partnership directly between the engineering teams. Of course, commercial aspects must also be taken into account, which is why ongoing coordination with purchasing and sales is necessary. Acal BFi therefore always provides customers with a technical project manager at MagTC and a local field sales engineer.
Important to know: once designed, production costs of customised cores or components are not significantly higher than for standard ones. Depending on complexity of project and product, NRE charges and tooling costs can be applied. However, these are often overestimated. Don’t hesitate to ask.
Absolutely — our in-house prototyping and stock for most materials enable quick (within a few days) and professional manufacture of functional samples, prototypes and even small series before full-scale production. These can then be extensively tested and measured. For this purpose, specific limit samples can also be produced and tested at the specification limits.
Whatever you need! As a standard, you’ll get data sheets, test reports, and usual material compliance certifications. On demand, we deliver extended documentation like PPAP, evaluation reports, simulation and design models – and even more.
Yes. Our engineers regularly help customers improve functionality or efficiency, replace materials, or miniaturise existing magnetic components. Or simply provide a second source.
New components are thoroughly tested in our laboratory, including samples and prototypes as well as first articles from series production. This applies to specified properties as well as standard parameters that are not specifically specified. We have extensive experience in the behaviour of materials and components under operational and different environmental conditions, as well as in terms of long-term properties. If we have any doubts about this, or if you would like product validation, this will be carried out in our laboratory or with certified partners. New products are then first approved internally at Acal BFi and then submitted to you for approval (design approval, production approval).
You place your order with your local Acal BFi contact person, who then forwards the order to MagTC. Our team manages the entire supply chain, i.e. we organise series production at the designated manufacturing site and transfer to our central warehouse in Dietzenbach, including customs clearance if applicable. For certain materials, we also take care of purchasing and transfer to the manufacturing site. Delivery from our central warehouse and options such as safety stock are organised by your local contact person.