From Module Selection to Discrete DC/DC Architecture

For many development projects, the module initially remains the obvious solution. A high level of integration shortens the development phase, simplifies layout and certification, and reduces the effort required for testing and validation. Especially when small to medium production volumes are planned or a product needs to be brought to market quickly, this approach is often economically and organizationally reasonable. Time to market is not a secondary argument in such cases, but often the central boundary condition.

With increasing volumes, however, priorities shift. Unit costs, thermal fine-tuning and close integration into the overall circuit gain importance. Particularly in volume-driven applications, discrete DC/DC topologies allow the transformer, switching frequency and layout to be specifically adapted to the respective application. As a result, both efficiency and thermal behavior can be improved while also reducing unit costs in series production. In many projects, the economic transition occurs at around 50,000 units: below this level, modules often remain the more economical solution, while above it the attractiveness of discrete architectures increases significantly.

In addition, there is a structural factor in electronics development: power stages are among the more demanding disciplines of analog design. Magnetic components, parasitic effects, switching transients, isolation and EMC must be mastered simultaneously. At the same time, experienced analog know-how is not available in unlimited quantities in many development teams. Modules have also become established because they shift a significant portion of this complexity into a tested component.

It becomes particularly interesting where developers want to combine the advantages of both worlds. This is exactly where RECOM introduces a discrete DC/DC architecture based on IC + transformer solutions that simplifies the transition from a ready-made DC/DC module to a discrete DC/DC power supply. The company transfers its integration and application know-how from the module world to discrete power supply solutions and provides a clearly defined functional chain for this purpose. At the center are three elements: a primary-side transformer driver IC, standard or custom transformers, and intelligent rectifier and controller components on the secondary side.

This enables the creation of a compact isolated auxiliary power supply with a manageable bill of materials. The driver IC generates the primary-side drive, the transformer handles energy transfer and galvanic isolation, and the secondary-side smart rectifier converts it into a stable DC voltage. In reference designs, the external circuitry can be limited to a few passive components. At the same time, the architecture remains flexible enough to implement different circuit concepts, such as push-pull, full-bridge or LLC-like configurations.

For developers, it is particularly relevant that RECOM not only provides individual ICs but also the corresponding magnetic component. The combination of IC + transformer significantly reduces effort in the concept phase, because key interfaces between control, magnetics and the secondary side can already be systematically aligned. If IC and transformer are sourced together, the components can be pre-tested for their interaction. This reduces iteration loops in development and supports faster design validation.

This results in a significant contribution to reducing development time. Instead of having to fully validate the suitability of a discrete topology from scratch, developers receive a predefined foundation that takes electrical and magnetic compatibility into account. Power transfer, input and output voltages, isolation requirements and height constraints can thus be addressed in a more structured way. For projects with high time pressure, this means that the path to a discrete solution becomes significantly shorter, without sacrificing the degrees of freedom for application-specific optimization.

This positioning is also noteworthy from a market perspective. RECOM is the only leading power supply manufacturer that offers both complete DC/DC modules and the corresponding discrete IC and transformer solutions from a single source. For customers, this creates a consistent migration path: those who initially start with a module can switch to a discrete architecture as volumes grow or target costs change, without having to completely rethink the technological basis.

Thus, the decision between module and discrete topology becomes less of an either-or and more of a development strategy across the entire product lifecycle. In early phases, a quickly available, tested solution is often key. In later phases, cost, thermal optimization and integration level may favor a discrete implementation. The approach aims to map this transition within a common technological basis instead of forcing developers to switch between two separate product worlds. When both options are aligned and come from the same supplier, interface effort is reduced – and this is where many developers see the practical benefit.

Not the form factor alone is decisive, but rather the question of which power supply architecture best fits the respective project phase, target market and planned production volume. RECOM addresses this relationship with an approach that combines time to market, discrete design freedom and the IC + transformer combination within a single portfolio. The core message is therefore not only that discrete solutions can be economically attractive, but also that entering them today requires significantly less development effort than just a few years ago.

Technically, the approach particularly addresses distributed power architectures and compact isolated auxiliary power supplies, such as those required in gate driver power supply applications for IGBTs, MOSFETs or SiC power semiconductors. In these application areas, isolation, dynamics, thermal margins and reproducible switching behavior are critical. A coordinated combination of driver IC and transformer therefore not only simplifies electrical design but also supports the transition into robust series production.

The DC/DC power supply market is not moving away from modules, nor is it universally shifting toward discrete solutions. Rather, the demand for scalable power supply concepts is growing, enabling different priorities depending on the project phase. Those who want to start quickly need a ready-to-use module. Those who later focus consistently on unit costs and application-specific optimization require a controlled transition to a discrete topology. This bridge between rapid market entry and technical design freedom defines the core of the RECOM approach.