7-Month Development of a 60 W Isolated Commercial Power Supply for Laboratory Use

Context & Challenge

In 2019, a biotechnology company based in Boston required a 60 W isolated power supply for a new electrophoresis system. Off-the-shelf options (both low-cost and high-end laboratory supplies) failed to meet the combined requirements for safety compliance, mechanical integration, and cost efficiency. The solution needed to comply with international laboratory instrument safety standards and support stable, repeatable production.

Process

• Regulatory analysis: Reviewed IEC 61010 and applicable safety requirements for laboratory instrumentation.

• Specification definition: Power, isolation, voltage and current ranges, size, and thermal performance.

• Electrical & PCB design: Selected an isolated topology, designed the magnetic components and did the CAD implementation of the PCB.

• Prototyping & bring-up: Loop stabilization network, transient behaviour, isolation verification and thermal performance.

• Design iterations: 5 revisions before the final production-ready version.

• Production transfer: Coordinated with manufacturer to ensure repeatability and quality.

Results

• 7 months from requirements definition to production-ready prototype.

• Product currently in manufacturing and active sales.

• Designed for compliance with international laboratory safety standards and EMC.

• Significant cost reduction compared to high-end market alternatives.