Comprehensive Capabilities for Custom Magnetic Solutions

Expert Design Services for Optimal Performance

At Vanguard Electronics, our experienced and knowledgeable engineering team specializes in designing RF, SHF, UHF, power, high voltage, and high temperature inductors and transformers, as well as other custom applications. We take your parameters or concept and create the most optimal design, considering reliability, manufacturability, performance, and cost. Our team can also develop Source Control Drawings (SCD) to streamline your project.

Custom Leadframe Design & Etching

Vanguard Electronics enhances the mechanical integrity of our products through custom leadframe design and etching. This approach improves the co-planarity of the package and ensures a secure bond from the coil to the internal leadframe, connecting to the exposed leads. Our in-house leadframe etching capabilities allow for maximum customization, bringing your design to life with precision.

Custom Tooling and Fixtures

With full-service machine shops in Huntington Beach and Mexicali, Mexico, Vanguard Electronics offers extensive capabilities in creating custom tooling and fixtures. We can tool a variety of heavy-duty materials such as aluminum and stainless steel for various applications, including:

  • Assembly Fixtures
  • Potting Cavities
  • Molding Cavities
  • Winding Mandrels
  • Inspection Fixtures
  • Forming/Trimming Dies
tooling_slider_1.jpg

Iron Powder Cores and Custom Forms

We provide a range of iron powder cores, including bobbins, coil forms, toroids, and rods. These components are essential for high-reliability inductors and transformers, tailored to meet your specific needs.

Custom Winding Options

Custom Winding

Vanguard Electronics has invested in a wide range of automated and manual winding machines, as well as hand-winding skill sets. Our custom winding options include:

  • Manual & Machine-wound options on bobbins, toroids, ceramic cores, solenoids, and more
  • Sector Wound
  • Evenly Distributed
  • Progressive Multifilar
  • Foil Wound
  • Layer Wound

We accommodate different tolerance levels and wire sizes ranging from 0 AWG to 55 AWG.

Custom Fabrication and Encapsulation

Our transfer molding process, perfected over decades, ensures consistent and reliable encapsulation of high-reliability inductors and transformers. This process involves designing and machining molding cavities to house the assembled units, followed by the injection of molding compound. Key benefits include:

  • Customized headers, sleeves, cases, and shells
  • Dimensional tolerances to 0.001″
  • Wide selection of materials and flammability ratings
  • Mounting options include leads, inserts, brackets, and others
  • Heat transfer mounting plates available
  • SMT, Gullwing or Thru-Hole terminations and finishes

Transfer Molding for High Reliability

Our transfer molding process is a consistent alternative to manual potting, ensuring reliability through repeatability and tighter tolerances on electrical and mechanical characteristics. This method is crucial for maintaining the high standards required in mission-critical applications.

Comprehensive Electrical Testing and Mechanical Screening

Electrical equipment is in-house and ready to test all types of products for Corona testing, DCR, DWV, Inductance, Impedance, SRF, S-Parameters, Turns Ratio, Polarity, Common Mode Rejection, Oscilloscope Analysis and other requirements for inductors and transformers. Testing capabilities range from frequencies of 1 Hz up to as high as 6 GHz and applied-voltages up to 50kV DC/AC.

Vanguard has fully developed AS9100 and ISO 9001 approved procedures for necessary equipment to meet all military and space standards for electrical testing and mechanical inspections

Cleanroom Facilities for Precise Testing

Our cleanroom environment is designed to test parts accurately up to 6 GHz, providing maximum control for performing failure analysis. The cleanroom is:
  • Suited for sensitive products in any industry
  • Easily upgradable to Class ISO 7 upon customer request
  • Specialized for material handling and inspection to medical and space grade standards/certifications, including MIL-STD-981 and ISO 13485

Why Choose Vanguard Electronics?

For over 70 years, Vanguard Electronics has been a trusted partner in the design, manufacture, and testing of high-reliability inductors and transformers. Our comprehensive capabilities, combined with our commitment to quality and reliability, make us the ideal choice for your custom magnetic solutions.

Connect with Us

If you need customized magnetic solutions that meet the highest standards of reliability and performance, contact our experienced engineering team today. Let us help you bring your design to life with precision and reliability. Keywords: custom magnetic solutions, high-reliability inductors, transformers, RF, SHF, UHF, power, high voltage, high temperature, custom leadframe design, custom tooling, iron powder cores, custom winding, transfer molding, electrical testing, mechanical screening, cleanroom facilities, AS9100, ISO 9001, MIL-STD-981, ISO 13485.

Contact Us

© 2025 VANGUARD ELECTRONICS. All rights reserved.