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We understand your concerns

High Voltage & Power Handling

Energy applications like EV chargers and inverters need PCBs that safely handle high voltage and current, with proper creepage/clearance and insulation.

Thermal Management

Energy applications like fast charging and high-power output (e.g., 65–200W) generate huge heat, making effective thermal management essential.

EMI/EMC Compliance

Power electronics often produce strong EMI. Effective layout, grounding, and filtering are essential to meet regulatory standards.

Reliability Under Real-World Use

Energy devices must operate safely in varied environments, which increases the importance of robust protection circuitry and quality assurance in layout.

Our Solutions

Advanced High Voltage & Power Handling Design

Enabling Safe and Efficient Energy Systems.

Creepage and clearance rules optimized for high-voltage safety.

Isolation strategies including slots, cutouts, and high-voltage-rated materials.

Precision current path design to reduce losses and overheating.

Compliance with IEC/UL safety standards for power electronics.

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Thermal Management Expertise

Keeping High-Power Systems Cool and Reliable.

Thermal simulations when necessary to predict and manage heat hotspots.

Thermal via arrays and copper pours for efficient heat dissipation.

Integration of heat sinks, thermal pads, and thick copper layers.

Distribute and isolate heat-sensitive components during PCB layout.

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EMI/EMC-Conscious Layout and Filtering

Ensuring Signal Integrity and Regulatory Compliance.

Optimized grounding, plane segmentation, and trace routing.

Power and ground plane isolation to contain switching noise and reduce coupling.

Shielding techniques for noise-sensitive areas.

Design validation against CE, FCC, and CISPR standards.

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Design for Real-World Reliability

Robustness Against Harsh Environmental Conditions.

Surge protection, TVS, and ESD safeguards integrated into the layout.

Use of moisture-resistant surface finishes and conformal coatings based on application environment.

Design validation for wide temperature and humidity ranges.

Quality control through ERC/DRC, electrical test, and manufacturing reviews.

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Our Design Service Workflow

Requirement Analysis

Gain a deep understanding of customer needs, analyze product functions, performance requirements, cost constraints, and timelines, and develop a detailed design plan.

PCB Layout

Perform PCB layout and routing design, considering signal integrity, power integrity, thermal management, and EMC factors to optimize PCB performance.

Prototyping and Testing

Produce PCB prototypes and carry out functional, performance, and reliability tests to verify the design's accuracy and stability.

Schematic Design

Design circuit schematics based on requirements, perform circuit simulation and validation if necessary, select appropriate components and optimize circuit performance.

Design Review and Optimization

Conduct multidimensional design reviews, including DFM, DFT, SI/PI, and EMC checks, and optimize the design based on the review results.

Mass Production Support and Maintenance

Provide production documentation and technical support, assist customers with mass production, resolve issues during the manufacturing process, and offer ongoing design maintenance services.

Successful Project Development Case

15W-wireless-charging-motherboard

Suitable for wireless charging bases, mobile phones, smart watches, car chargers, etc., with multiple safety protections, such as temperature protection, anti-reverse protection, FOD metal object detection, etc.

Size 30*25mm

Chip IP6808

8%Time saved by

7kw-charging-pile-motherboard

It has a rich peripheral expansion interface, can be equipped with industrial-grade display screen, card reader, etc., ultra-low standby power, and multiple safety protections, and built-in hardware watchdog.

Size 142mm*142mm

Chip ARM Cortex-M4F

13%Performance enhanced by

GaN-PD-30W

Input:100–240V Output:5V⎓3A, 9V⎓3A, 12V⎓2.5A, 15V⎓2A, 20V⎓1.5A Port A Charging Protocols: QC3.0 Port C Charging Protocols: FCP, SCP, AFC, QC3+, PD3.0, DCP.

Size 38.5*34.5

Chip MK2787

19%Size reduced by

GaN-PD-65W

Input: 100–240V Output: 5V3A, 9V3A, 12V3A, 15V3A, 20V3.25A Port A Charging Protocols: QC3.0, QC2.0, DCP, AFC, FCP, SCP, APPIe2.4A, Samsung-2.0A Port C Charging Protocols: FCP, SCP, AFC, QC3+, PD3.0.

Size 56*55

Chip MK2789IDG

16%Quality improved by

300W Portable Outdoor Emergency Power Station

Power 300W, ternary lithium battery cells, multiple output ports, compatible with various devices, supports PD 60W fast charging, built-in inverter, equipped with independent AC switch.

Size 24.5*12*14.5cm

Chip CS32F030C8T6

16%Quality improved by

What can PCBWay do for you?

Professional Engineering Team

Our engineering team consists of experienced engineers in electronics, embedded systems, and product development. We've successfully delivered hundreds of projects across industries such as medical devices, industrial automation, consumer electronics, smart home, and IoT.

End-to-End Development

From concept to production. Our services cover schematic development, PCB layout, embedded firmware development, mechanical design, prototyping&testing, and final DFM optimization. This approach coudl ensure faster time-to-market, better coherence, reliability, and lower cost.

Fast Turnaround

With a skilled engineering team and in-house manufacturing, we deliver high-quality prototypes and production-ready designs fast. From concept to delivery, we prioritize speed, quality, and reliable lead times to keep you ahead of the competition.

Manufacturing Advantage

We own PCB, assembly, CNC, and injection molding factories, giving us full control from design to mass production. This ensures faster delivery, high quality, and lower costs. With in-house assembly, testing, and QC, we smoothly scale from prototypes to volume production

Long-Term Value Program

We support your product's full lifecycle with upgrade discounts, ongoing technical support, and a permanent 5% PCBA discount for design orders.With us, you gain more than a design service; you gain a technology partner for the entire lifecycle of your product.

Create value with many customers

10+

Industry Experience

20+

Professional Engineers

1000+

Successful Projects

Get an instant quote Customer cases

“Their PCB layout for our high-voltage EV charger was spot-on — optimized for thermal performance and fully compliant with UL standards. Truly professional work.”

@Daniel O’Connor Senior Hardware Engineer

"We needed a fast turnaround for a 120W GaN charger prototype. Their team delivered high-density, thermally stable designs within days — very impressed with the quality and speed.”

@LiamProject Manager

"Their experience in HDI and high-density layout made a huge difference for our slim smartphone accessory. We went from concept to prototype in record time."

@RobertBrown Hardware Engineer

“From concept to testing, their design support was thorough and responsive. They handled our complex multi-layer charger board with precision.”

@Joseph SandersCarter Senior Hardware Engineer

Industries we work

Consumer Electronics

Including smart wearables, smartphones, tablets, audio devices, and smart home products, etc.

Industrial Automation

Including control systems, sensors, PLC modules, motor drivers, and industrial communication devices.

Medical Electronics

Including patient monitors, portable diagnostic devices, wearable health trackers, and medical imaging equipment.

Automotive Electronics

Including ECUs, dashboard systems, ADAS modules, EV chargers, and in-vehicle infotainment systems.

Internet of Things (IoT)

Including smart sensors, connected home devices, asset trackers, and remote monitoring systems.

Energy

Including solar power controllers, battery management systems, EV power modules, and smart metering devices.

Frequently Asked Questions

How do you address EMI/EMC issues in energy applications?

We implement proper grounding, shielding, differential pair routing, filtering, and layer stack-up optimization to minimize electromagnetic interference and ensure compliance with EMC standards.

What types of energy charger applications do you support?

We design PCB for EV chargers (AC and DC), onboard chargers (OBC), battery management systems (BMS), solar inverters, power converters, and energy storage systems.

Do you support isolated and non-isolated power designs?

Absolutely. We design for both isolated (transformer or opto-isolated) and non-isolated topologies, ensuring safety and functional reliability.

What is the typical lead time for a energy PCB design?

Depending on the complexity of the project, electronic design typically involves several stages: schematic design, PCB layout, embedded development and prototype debugging.

Do you provide end-to-end support from design to manufacturing?

Yes, our services cover concept development, schematic and layout, prototyping, DFM/DFT reviews, and support through mass production.

Do you offer confidential and IP-safe design services?

Yes, We treat all customer data with strict confidentiality and can provide a Non-Disclosure Agreement (NDA) or Intellectual Property (IP) Transfer Agreement upon request.

Start your project design in 3 steps

Step 1: Choose service and submit requirements.: Please select whether you need Layout, PCB Design, or Mechanical/Enclosure Design, and submit your design requirements.

Step 2: Confirm details and get a quote.: Our engineers will evaluate the project, confirm the technical details, and provide a quotation.

Step 3: Pay to kick off the design: After payment, we will start the project design and provide regular progress updates.

Great Products Start with Great Hardware

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Professional PCB Design for Energy

We understand your concerns

High Voltage & Power Handling

Thermal Management

EMI/EMC Compliance

Reliability Under Real-World Use

Our Solutions

Advanced High Voltage & Power Handling Design

Thermal Management Expertise

EMI/EMC-Conscious Layout and Filtering

Design for Real-World Reliability

Our Design Service Workflow

Requirement Analysis

PCB Layout

Prototyping and Testing

Schematic Design

Design Review and Optimization

Mass Production Support and Maintenance

Successful Project Development Case

15W-wireless-charging-motherboard

7kw-charging-pile-motherboard

GaN-PD-30W

GaN-PD-65W

300W Portable Outdoor Emergency Power Station

What can PCBWay do for you?

Create value with many customers

@Daniel O’Connor Senior Hardware Engineer

@LiamProject Manager

@RobertBrown Hardware Engineer

@Joseph SandersCarter Senior Hardware Engineer

Industries we work

Frequently Asked Questions

Start your project design in 3 steps