Switch Mode Power Supplies (SMPS) Assembly

Accelerate your product launch with Frigate’s tier-1 Switch Mode Power Supply (SMPS) assembly services, engineered for maximum thermal efficiency and rugged industrial reliability. From high-density PCB population to rigorous functional testing, we deliver custom power electronics tailored to your exact performance benchmarks.

Topology Support

Flyback, Forward, Push-Pull, Half-Bridge, Full-Bridge, LLC Resonant

Input Voltage Range

85 VAC – 264 VAC (Universal Input), 9 VDC – 72 VDC (Custom DC-DC)

Output Power Rating

5W up to 5kW+ continuous

Efficiency Standards

Up to 94%+, 80 Plus Platinum/Titanium compliant designs

Switching Frequency

50 kHz to 500 kHz+ (utilizing SiC/GaN capabilities)

*Note: Timelines are indicative and depend on component availability and design complexity. Standard turnarounds assume all long-lead items are readily available.

Product Description

Frigate specializes in the end-to-end contract manufacturing and turnkey assembly of high-performance Switch Mode Power Supplies designed to handle demanding electrical environments. Our state-of-the-art SMT lines and rigorous quality control ensure that every power module delivers clean, stable DC output with minimal thermal dissipation.

PCB Assembly Standards

IPC-A-610 Class 2 and Class 3 (Medical & Aerospace)

Component Footprint

SMT down to 01005, BGA, Micro-BGA, QFN, Through-Hole (THT)

Thermal Management

Aluminum clad PCBs, heavy copper layers, custom heatsink extrusion

Dielectric Withstand

Input-to-Output: 3K VAC – 4K VAC (Enhanced isolation)

Protective Features

OVP (Over Voltage), OCP (Over Current), SCP (Short Circuit), OTP

Potting & Coating

Conformal coating (Acrylic, Silicone, Polyurethane), Epoxy potting

Testing Protocols

ICT (In-Circuit), Automated Optical Inspection (AOI), X-Ray, Flying Probe

Burn-In & Environmental

Full-load elevated temperature burn-in, thermal cycling stress testing

Compliance & Certifications

Designed for UL 62368-1, CE, RoHS, REACH, FCC Part 15 Class B

Manufacturing Scale

Low-volume prototyping to high-volume automated box-build assembly

Technical Advantages

By integrating advanced Silicon Carbide (SiC) and Gallium Nitride (GaN) switching technologies, our assemblies achieve ultra-high power densities within compact mechanical footprints. Furthermore, our robust design-for-manufacturing (DFM) protocols optimize component placement to significantly reduce electromagnetic interference (EMI) and cut overall production costs.

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Industry Applications

Industrial Automation

Reliable DIN-rail and open-frame SMPS modules designed to drive PLC systems, robotics, and rugged control panels in harsh factory environments.

Telecommunications

High-density, low-noise DC-DC converters and rectifiers engineered for continuous, zero-downtime operation in telecom towers and data centers.

Medical Devices

IPC Class 3 compliant power assemblies featuring low leakage current and high isolation barriers for critical diagnostic and life-support equipment.

Electric Vehicles (EVs)

On-board chargers and ruggedized auxiliary power modules built to withstand extreme thermal cycling, mechanical vibration, and shock.

Renewable Energy Systems

High-efficiency power conditioning micro-inverters and charge controllers optimized for solar grid-tie interfaces and wind energy storage.

Aerospace & Defense

Custom-engineered, lightweight power supplies built to defense-grade standards, featuring advanced conformal coating and potting for extreme altitudes.

Frigate Approved Quality Management System

At Frigate, quality is built into every stage of manufacturing. Our approved Quality Management System ensures that every material component.

Incoming Material Checking

Before production begins, all incoming materials are checked against specifications, drawings, and supplier documents.

In-Process Inspection

Quality is monitored during manufacturing to prevent defects and maintain process consistency.

Final Dimensional Checking

Finished parts are inspected before dispatch to confirm compliance with customer drawings and tolerances.

Packaging Control

Finished components are packed safely to prevent damage during handling and transportation.

Incoming Material Checking

In-Process Inspection

Final Dimensional Checking

Packaging Control

Quality Document

To help buyers evaluate our quality systems, we provide sample documents that reflect our inspection and reporting standards.

How We Delivered

Complex geometries engineered solutions that move businesses forward.

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Bento Boxes for D2C Segment

Units Manufactured Monthly

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Defence-Grade Cable Supply

Cost savings

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Flange Assembly for Pump

Faster Production

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Having Doubts? Our FAQ

Does Frigate support compliance testing for CE, UL, or FCC certification?

While we operate as a contract manufacturer, we build your SMPS assemblies strictly to the design rules required for regulatory compliance. We provide full traceability documentation, material certificates, and test reports (such as Hi-Pot and functional test logs) needed to streamline your final product certification process.

How does Frigate ensure the reliability and safety of high-voltage power assemblies?

Every SMPS assembly undergoes stringent testing pipelines, including automated optical inspection (AOI), in-circuit testing (ICT), and high-voltage dielectric isolation (Hi-Pot) testing. For production batches, we conduct automated full-load burn-in testing to eliminate early-life component failures before shipment.

Do you support design optimization for thermal management and EMI reduction?

Yes, our engineering team conducts comprehensive Design for Manufacturing (DFM) and thermal layout reviews before production. We optimize trace widths, copper weights, component spacing, and heatsink interfaces to minimize electromagnetic interference and maximize heat dissipation.

What custom magnetic and transformer options do you support?

Power supply performance depends heavily on the magnetics. We support the assembly and integration of custom-wound planar transformers, toroidal inductors, and specialized chokes to meet your specific switching frequencies and efficiency profiles.

Are Frigate’s SMPS assemblies compliant with global environmental regulations like RoHS and REACH?

Yes, we offer full compliance tracking. We verify that all components, solder pastes, fluxes, and conformal coatings used in your power supply assembly meet strict RoHS and REACH directives, providing complete declaration documents upon request.

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Components Built for Critical Performance

Engineered Products for Critical Applications

Switch Mode Power Supplies (SMPS) Assembly

Product Description

PCB Assembly Standards

Component Footprint

Thermal Management

Dielectric Withstand

Protective Features

Potting & Coating

Testing Protocols

Burn-In & Environmental

Compliance & Certifications

Manufacturing Scale

Technical Advantages

Let's Get Started

Industry Applications

Frigate Approved Quality Management System

Quality Document

How We Delivered

Having Doubts? Our FAQ

We'd love to Manufacture for you!

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

Get Your Quote Now

Switch Mode Power Supplies (SMPS) Assembly

Get Latest Price

Switch Mode Power Supplies (SMPS) Assembly

Get Latest Price