Smaller Core, Bigger Profits: Why Size Reduction Starts at the Magnetic Core

In power electronics, space is no longer a luxury—it's a constraint. And yet, many designers still use bulky ferrite cores that take up board space, raise heat issues, and inflate enclosure costs.

There’s a better way.

What If Your Magnetic Core Was 45% Smaller?

Nanocrystalline cores from Dongguan JH Amorphous are engineered for compact, high-frequency applications. Compared to traditional ferrite:

• 📦 Up to 45% smaller in volume

• ⚖️ Up to 47% lighter

• 🔌 Supports higher current density in tighter spaces

• 🌡️ Less heat = less thermal management overhead

Smaller cores help reduce:

• PCB size

• Enclosure volume

• Cooling requirements

• EMI filter footprint

Real-World Results

A customer in Japan redesigned a 2kW solar inverter using our nanocrystalline core.
Result: 22% smaller casing, 12% lower BOM cost, and EMI passed on the first try.

Another client in Germany eliminated a fan unit—just by reducing core losses and switching to a smaller core.

Size Reduction Is About More Than Space

When you reduce magnetic component size, you enable:

• 🔋 Higher power density

• 📐 Simpler mechanical design

• 💰 Reduced materials cost (less copper, less plastic)

• 📦 Lower shipping weight and volume

In short: smaller magnetic cores ripple across your entire product architecture.

Why Ferrite Can’t Keep Up

Ferrite cores:

• Have lower flux density (Bs ~0.4T)

• Saturate faster under current peaks

• Struggle with EMI above 2 MHz

• Are bulkier for the same impedance or inductance

In contrast, nanocrystalline cores offer Bs ≥1.2T, excellent frequency range (10kHz–30MHz), and can handle more with less material.

Applications That Demand Miniaturization

• EV onboard converters (space-constrained bays)

• PV inverters in wall-mounted units

• Compact high-frequency SMPS

• Medical or defense systems where size = mission-critical

Shrink the Core, Grow the Margin

Designers often think of magnetic cores as fixed assets—what if they were your leverage?

Shrinking the magnetic core shrinks the whole system.
And smaller systems are faster to build, cheaper to ship, easier to cool—and easier to sell.

 

👨‍🏭 Author:

Julia Yim
International Marketing Manager
Dongguan JH Amorphous Co., Ltd.
📧 julia@amorphousoem.com | 🌐 www.amorphousoem.com