Exxelia - Continuous progress in the field of integrated magnetic components for innovative topologies for power converters

Since the beginning of 2024, the engineering teams at our manufacturer, EXXELIA, have been developing the first Smart Integrated Magnetics. Progress has been continuous since then, and the design method has been significantly improved. A set of design rules for Smart Integrated Magnetics has been established, reducing the number of simulations required during development and saving resources and time. This means more efficient and reliable development processes in the field of Smart Integrated Magnetics.

A key parameter in this process is the ratio between the resonant and magnetising inductances. Based on these new rules, the EXXELIA team can now make initial technological design decisions based on customer-requested specifications. The simulation is then only used to fine-tune and calculate important values such as inductances and eddy current losses.

First steps already taken in the development of integrated magnetic for dual active bridge (DAB) power converters in 2024

Back in 2024, Exxelia presented the first steps towards developing integrated magnetic for DAB power converters. The company emphasised that DAB power converters are being used increasingly instead of traditional topologies  in energy storage and power systems because they enable bidirectional energy transmission, galvanic isolation, and greater efficiency and power density. However, DAB power converters require an inductor to be connected in series with a transformer. Innovative integrated magnetics offer a solution to this, combining inductor and transformer functions in a single component and offering the following advantages:

• Reduced volume and weight (more than twice as light as two discrete components)
• Improved efficiency
• Simplified assembly and integration
• Better thermal management
• Optimised electrical performance for high frequency resonant converters

The current status of EXXELIAs Combined Magnetic Integrated

EXXELIA has successfully developed six CMIs (Combined Magnetic Integrated or Smart Magnetics), three of which were ready for use immediately after testing. Two more are currently being manufactured and tested. These converters cover a power range of 1–25 kW and operate at frequencies of 100–320 kHz.

More about EXXELIA's smart magnetics integrated technology – current products

3 Phase 24 kVA Integrated Component (Transformer + Inductors) 360/27 V @ 100 kHz

• High Power Applications (up to 300 kW)
• High Frequency (10-500 kHz): fits next-generation semiconductors (SiC, GaN) : Enables compact, lightweight designs.   
• High Efficiency: minimizing losses, achieving efficiencies above 99% even at high frequencies.
• Lower Total cost of ownership: Ensuring straightforward integration and optimized system costs.
• EMI Reduction: Enhances electromagnetic compatibility for reliable operation.

Dual Active Bridge Transformer 2 kW / 10:1 / 300 kHz and Chokes 10 µH

• High Power Applications (up to 300 kW)
• High Frequency (10-500 kHz): fits next-generation semiconductors (SiC, GaN) : Enables compact, lightweight designs.   
• High Efficiency: minimizing losses, achieving efficiencies above 99% even at high frequencies.
• Lower Total cost of ownership: Ensuring straightforward integration and optimized system costs.
• EMI Reduction: Enhances electromagnetic compatibility for reliable operation.

Further information on Smart Magnetics and the products presented can be found on our dedicated information page: https://msa-components.com/showcase/smart-magnetics/

EXXELIA's Smart Integrated Magnetics Solution at the Space Tech Expo 2025

As in previous years, MSA Components and our manufacturer, Exxelia, will be exhibiting at Space Tech Europe. Alongside its current range of capacitors, inductors and EMI filters, Exxelia will present its latest innovation in magnetic components. You will have the opportunity to learn more about integrated magnetic component technology and smart magnetics products from our team and the Exxelia team on site. You can also find out about the latest products, qualification requirements, and customised solutions for next-generation spacecraft and the wider aerospace industry.

Please visit our stand to meet us in person and discuss your projects and challenges, and find out how MSA Components can support you with the latest technological innovations on the market.

You will find us at booth number F11.
Of course, you are welcome to schedule an appointment with us beforehand.