In-House Fabrication & Assembly
By executing sheet metal fabrication, CNC machining, magnetic component winding, and SMT circuit board placement under one roof, we eliminate overseas supply chain delays and maintain strict quality standards.
American Engineering & Manufacturing Excellence
Vertically Integrated USA Manufacturing Facility
Complete in-house control over precision engineering, surface-mount assembly, magnetics winding, and full-power burn-in testing in Flemington, New Jersey.
The Magna-Power Manufacturing Advantage
Four Decades of Direct Quality & Supply Chain Control
For international procurement officers and research institutes, component provenance and manufacturing reliability are critical. Magna-Power operates a fully vertically integrated facility spanning 100,000+ sq ft in the USA, ensuring 4–6 week made-to-order lead times, complete quality traceability, and long-term product serviceability.
100% Full-Power Burn-In Testing
Every unit undergoes extensive functional testing, insulation breakdown verification, and full-power load testing prior to shipment to ensure zero-defect commissioning at client test bays worldwide.
Long-Term Reliability & Support
With direct ownership of engineering and production, Magna-Power guarantees long-term spare parts availability, standardized SCPI command sets, and regional repair support globally.
Production Departments
Inside Our USA Production Facility
Discover how raw materials are transformed into industry-leading high-power programmable DC power supplies and linear electronic loads.
Sheet Metal & Thermal Management Fabrication
Our sheet metal processing department processes raw steel, aluminum, and copper sheets into durable chassis enclosures and high-performance heatsinks. CNC shearing, automated tool-changing turret punch presses, and high-tonnage press brakes deliver exact mechanical tolerances.
Core Manufacturing Capabilities:
- Automated turret punch presses with multi-tool changing stations
- High-tonnage press brake bending for heavy-gauge power enclosures
- Electrostatic powder coating with iron-phosphate wash pretreatment
- Robotic bonded-fin heatsink assembly with automated thermal epoxy dispensing
Surface-Mount & Through-Hole PCB Assembly
Control boards and high-power circuit assemblies are assembled in-house using automated Surface-Mount Technology (SMT) and selective soldering systems designed for high-mix, high-reliability power electronics manufacturing.
Core Manufacturing Capabilities:
- High-speed SMT pick-and-place placement with Europlacer inline systems
- 7-zone nitrogen-capable reflow ovens and selective soldering machines
- CyberOptics 3D Automated Optical Inspection (AOI) for 100% joint verification
- Dual through-hole insertion lines dedicated to high-current power stages
Precision CNC Machining & Wire EDM
Heavy copper bus bars, liquid-cooled cold plates, and high-voltage insulating hardware are precision machined using multi-axis CNC vertical and horizontal machining centers, ensuring optimal electrical conductivity and mechanical fit.
Core Manufacturing Capabilities:
- CNC vertical and horizontal machining centers with automated probing
- Wire Electrical Discharge Machining (EDM) for intricate copper profiles
- Certified welding stations for heavy structural rack framework
- Custom wood-working machinery for international export crate fabrication
Automated Cable Harnessing & Sub-Assembly
Precision wiring harnesses and interconnect assemblies are manufactured using automated processing machinery. Every control and power harness is verified for insulation safety and point-to-point continuity prior to main chassis installation.
Core Manufacturing Capabilities:
- Automated wire cut, strip, and crimp processing stations
- High-voltage insulation and continuity testing for all cable looms
- Standardized modular harness boards for rapid custom system configuration
- Dedicated resistor module and sub-chassis build lines
Custom Magnetics Winding & Vacuum Impregnation
Magna-Power designs and winds 100% of its inductors, transformers, and harmonic neutralizers. Custom magnetic components are optimized for medium-frequency current-fed topologies, supporting systems up to 10 MW+.
Core Manufacturing Capabilities:
- Large-scale foil and rectangular wire winding up to 1 MW single-unit ratings
- Automated core production using AEM Unicore grain-oriented steel technology
- Precision brazing stations for water-cooled magnetic structures
- Vacuum Pressure Impregnation (VPI) and thermal curing in explosion-proof ovens
Final System Assembly & Cabinet Integration
Sub-assemblies, magnetic components, PCB stacks, and thermal modules are integrated on batch assembly lines. Digital tablet-driven assembly instructions guide technicians at every step to eliminate assembly variances.
Core Manufacturing Capabilities:
- Ten batch assembly stations for standard rack-mount instruments
- Dual push-assembly lines for high-volume manufacturing runs
- Heavy cabinet integration bays for multi-megawatt MT and ML Series units
- Integrated fluid manifold assembly for liquid-cooled power systems
100% Full-Power Burn-In & Traceable Calibration
Every product undergoes complete functional validation, automated safety checks, and sustained full-power load testing. Our test facilities feature heavy power infrastructure and closed-loop liquid cooling systems.
Core Manufacturing Capabilities:
- Eight high-power testing bays capable of continuous megawatt load profiles
- Ethernet-controlled electronic load banks and automated test software suites
- Closed-loop 1,000-gallon water recycling loop for liquid-cooled testing
- Full-spectrum safety high-potential (Hi-Pot) and calibration certification
Global Logistics & Export Compliance
Finished goods and sub-assemblies are managed in our 20,000 sq ft logistics facility. Real-time ERP tracking, automated guided vehicles (AGVs), and export-grade packaging guarantee safe international delivery.
Core Manufacturing Capabilities:
- Real-time barcode inventory picking integrated directly into corporate ERP
- Autonomous mobile robots for internal material transportation
- ISPM-15 compliant wood packaging for international freight protection
- Worldwide logistics compliance covering EU, APAC, and Americas destinations
Partner with a World-Class Power Electronics Manufacturer
Need custom voltage/current configurations, high-voltage bus supplies, or megawatt power solutions? Speak directly with our applications engineering team today.