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Magnetics Component Assemblies


Falco Electronics has years of experience in stamping and forming of aluminum panels and then riveting or assembling these panels together with screws to form racks or boxes. These capabilities allow us to combine multiple filter inductors and power inductors in one structure. When using these aluminum boxes we have developed techniques for encapsulating these large inductive components with different epoxies to meet different UL insulation system requirements and different thermal efficiency requirements

During the development process of these larger magnetic assemblies we work closely with the end customer's Electrical and Mechanical engineering team to make sure that our proposal will meet both their electrical and thermal needs and will fit in the space they have available. We have implemented ways of removing the heat from the entire magnetic component assembly to allow for a lower thermal conductivity rating.


The magnetic component assemblies are used in UPS, Inverters, and similar high power applications.


  • Wide range of assembly enclosure sizes available.
  • Rack assemblies put together with screws and aluminum panels up to 0.250" thick.
  • Aluminum boxes are riveted together
  • Power handling capability up to 1,000 KVA
  • Use of UL recognized 130C, 155C and 180C epoxies and UL insulation systems
  • Internal core loss and noise loss testing

2 Power Inductors assembled in aluminum box with 10AWG lead wire. (Inverter)

10 Inductors assembled in aluminum box with power capability up to 100KVA. (UPS)

2 DC chokes welded together with terminal block. (Inverter Drives)

3 Ferrite Choke, 3 Power Chokes, 2 Boost Choke all assembly together with power ranging from 40-160 KW. (UPS)

2 DC Chokes stacked together with 8AWG flexible lead wire. (Inverter Drives)