Vertically Integrated American Manufacturing
We don't just design power supplies; we make them.
At Magna-Power Electronics, we take immense pride in our complete control over the manufacturing process—every critical step happens under one roof. This degree of vertical integration is the product of over four decades of power electronics and manufacturing experience, spanning everything from custom magnetics winding to advanced surface-mount PCB assembly, all performed in-house. By merging hardware and software competencies, we ensure maximum scalability and continuous innovation across our broad product line, which now ranges from 1.25 kW to over 10 MW+. Our commitment to quality, backed by ongoing investments in state-of-the-art machinery and automation, has made Magna-Power Electronics a trusted name for robust, highly configurable programmable DC power supplies.
We invite you to explore our manufacturing departments through a series of videos, offering a behind-the-scenes look at how we transform raw materials into industry-leading power solutions. You’ll see how our dedicated engineering and manufacturing teams collaborate to uphold rigorous standards at every stage, from concept to final testing. This focus on craftsmanship and cross-department synergy is what enables Magna-Power to confidently stand behind every product we ship—delivering unmatched performance and reliability to customers worldwide.
Proudly Made in the USA
Flemington, New Jersey
Sheet Metal
Sheet Metal Department
The Sheet Metal Department transforms sheet steel, aluminum, copper, and fiberglass into finished components through processes starting with shearing to cut raw materials to size and multiple auto-tool-changing turret punch presses for creating detailed punch patterns. Metal sanding deburrs and prepares surfaces for powder coating, which includes an iron phosphate wash, ground plane masking, electrostatic powder application, and baking for a highly durable finish. A high-tonnage press brake provides accurate bending, while fastener insertion with automated vibratory bowl feeders ensures secure hardware placement. Adding further depth to this department’s capabilities is a robotic bonded fin heat sink assembly, featuring internally developed automation with a robotic arm and automated epoxy dispensing, as well as pad printing to finalize the completed parts.
Primary operations:
- Shearing operations to cut sheets to size
- Tool-changing turret punch presses
- Metal sanding for deburring and powder coating prep
- High-tonnage press brake for bending
- Fastener insertion with vibratory bowl feeders
- Powder coating (iron phosphate wash, masking, electrostatic spray, bake)
- Robotic bonded fin heat sink assembly
- Pad printing
Printed Circuit Board
Printed Circuit Board Department
From surface-mount to large power components, complete placement and inspection onto printed circuited boards, optimized for Magna-Power's low-to-medium volume high-mix requirements.
- Europlacer stencil printer and IINEO pick and place for SMT components
- 7-zone Heller reflow oven
- CyberOptics 3D automated optical inspection
- Three (3) rework stations and four (4) manual soldering stations
- Two (2) through-hole insertion lines for power components
- Nordson SELECT selective soldering system
- ITW Electrovert wave soldering
Machining
Machining Department
The Machining Department brings raw materials to life through precision processes and equipment, using advanced CNC vertical machining centers—complete with extended tool magazines, auto-probing, and the capability for wet machining on copper, aluminum, and steel, as well as dry machining for insulating fiberglass. Milling of front panels, mounting holes for semiconductors in heat sinks, and the manufacture of various bus bar assemblies are all performed here with remarkable accuracy. For especially intricate components, Wire EDM employs a thin wire and controlled electrical discharges to produce complex shapes and tight tolerances. This department also handles welding of heavy-gauge steel for rack enclosures, a CNC horizontal machining center dedicated to high-voltage insulators, and comprehensive wood-working operations for custom packaging. Additionally, saw operations efficiently cut bulk metal to size for downstream processes.
Primary operations:
- CNC vertical machining centers (wet/dry machining)
- Wire EDM for intricate parts
- Welding of heavy-gauge steel rack enclosures
- CNC horizontal machining for high-voltage insulators
- Wood-working for custom packaging fabrication
- Saw operations for cutting bulk metal to size
Sub-Assembly
Sub-Assembly Department
Wire harnessing and preparation of multiple assemblies for installation into the final product.
- Schleuniger automated cut, strip and crimp for all power and control cables
- Functional and high voltage wire testing
- Fourteen (14) assembly stations
- Resistor module manufacturing
- Internally developed wire harness boards for all products
Magnetics
Magnetics Department
The Magnetics Department is the heart of Magna-Power’s vertical integration, where raw copper and grain-oriented steel are transformed into high-performance power components. This department manages the end-to-end production of all magnetic elements, ranging from high-volume made-to-stock (MTS) inductors, chopper chokes, and EMI filters to complex, made-to-order (MTO) harmonic neutralizers and model-specific transformers. Capabilities span a vast power spectrum, supporting both air- and water-cooled designs for applications up to 1 MW. Using a mix of proprietary winding stations for rectangular wire and foil, alongside specialized high-frequency centers capable of simultaneous 20-strand winding, the department ensures precision at every scale. Advanced core production—utilizing AEM Unicore technology and distributed air gap designs—optimizes magnetic paths for medium-frequency efficiency. Every unit undergoes rigorous assembly, precision brazing for liquid-cooled thermal systems, and vacuum varnish impregnation before final validation and high-potential (Hi-Pot) testing to ensure long-term reliability in the field.
Primary operations:
- Large-scale winding for rectangular wire and foil (up to 1 MW)
- High-frequency winding for multi-strand ferrite core designs
- Automated core production using AEM Unicore and grain-oriented steel
- Precision brazing and fabrication for water-cooled magnetics and liquid-piping systems
- Vacuum varnish impregnation and curing in large-scale explosion-proof ovens
- Custom shunt fabrication for precision current sensing
- Comprehensive validation including integration testing and Hi-Pot safety certification
Final Assembly
Final Assembly Department
Production lines for installation and interconnection of completed assemblies into the final product.
- Ten (10) batch assembly lines for low-volume orders
- Two (2) multiple operator push assembly lines for medium-to-high volume orders
- Panelized production for MT Series
- Tablet-based work instructions mounted to every production line
Testing
Testing Department
Board-level and final product testing, calibration and burn-in.
- Eight (8) internally developed high-power test stations
- Ten (10) 75 kW Ethernet-controlled bulk load banks
- Three (3) 100 kW MagnaLOAD DC electronic loads
- Internally developed automated testing and calibration software suite
- 1000-gallon water tank recycler for water-cooled product testing
Logistics
Logistics
Raw material, component, sub-assembly and partially complete assembly.
- 20,000 sq-ft of warehousing and stock
- Two (2) autonomous inventory robots for inter-company transport
- Internally developed Android picking app with real-time ERP integration