Custom High Voltage Pulse Transformer Manufacturing

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Custom High Voltage Pulse Transformer Manufacturer

Custom High Voltage Pulse Transformers

Custom high voltage pulse transformers are specialized components designed to deliver controlled, high-energy pulses with precise timing and insulation requirements for demanding applications.

Key Design Features of Custom High Voltage Pulse Transformers

Customizable specs: Primary to secondary turns ratio, winding inductance, leakage inductance, and resistance to tailor pulse width, amplitude, and timing.
Frequency range and isolation: Transformers can be optimized for desired pulse width, repetition rate, and insulation type (oil-cooled, epoxy-coated, air/water insulation).
High-voltage performance: Modern designs support up to 1.5 MV, 6 kA, and 600 kVA, with rise times as low as 0.5 microseconds and ripple below 0.15% p-p.
Construction options: Through-hole mounting for PCB integration, vacuum potting, ground shielding, and double secondary windings for multi-output gate drives.

Leightner Engineering & Design

To suit your unique application requirements, Leightner Electronics offers engineering support to tailor transformers for your voltage, pulse shape, frequency range, and environmental needs. All of our unique high voltage transformers are engineered and manufactured in-house at our facility in McKinney, Texas, where we also maintain full control over all engineering, prototyping, design and development. Just provide us with your electrical requirements: desired voltage output, pulse duration, repetition rate, insulation/encapsulation, physical dimensions, and performance targets like rise time and distortion. To find out how Leightner may help your transformer needs, call 972-542-0176 or contact us!

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What is a High Voltage Pulse Transformer?

A high voltage pulse transformer is a specialized type of transformer designed to generate and transmit electrical pulses at very high voltages, often ranging from several kilovolts up to hundreds of kilovolts. These devices are optimized for short-duration, high-frequency pulse applications, such as triggering power semiconductors, radar equipment, medical devices, and high-energy physics experiments

Key Features of High Voltage Pulse Transformers

High-voltage output: Pulse transformers can produce output pulses reaching several thousand volts or even higher, which are needed for applications like ignition, charging circuits, and arc welding.
Fast transient response: They are designed to respond quickly to rapid changes in pulse currents and voltages, maintaining accurate signal transmission with minimal distortion.
Electrical isolation: Pulse transformers provide isolation between circuits while transmitting pulses, helping to protect sensitive electronics from high voltages.
Excellent insulation: These transformers are built with high insulation ratings to prevent breakdowns and interference when used at elevated potentials.

Differences From Conventional Transformers

Feature	Pulse Transformer	Power Transformer
Purpose	Transmits high-voltage pulses	Transfers continuous AC power
Core Material	Ferrite (low loss at high frequency)	Laminated iron/silicon steel
Output Waveform	Fast-rising pulses, square waveforms	Sinusoidal AC
Frequency Range	kHz to MHz (high frequency)	50 Hz or 60 Hz (low frequency)
Application	Gate drives, communication, radar, switching	Grid power, appliances

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Applications for High Voltage Pulse Transformer

High voltage pulse transformers are specialized components used to transfer short, high-energy pulses—often at voltages from tens to hundreds of kilovolts—with precise timing and minimal distortion. Their key value is in preserving pulse shape and delivering electrical isolation, which is essential in several demanding and critical applications.

High voltage pulse transformers are fundamental to radar modulators, driving magnetrons, klystrons, and electron guns that require precisely timed, high-voltage pulses for operation. These systems are critical in both military and civilian radar installations, as well as particle accelerators used in scientific research.

In robotics, servo drives, and automated manufacturing, pulse transformers isolate control circuits from power electronics. This separation prevents noise interference and ensures safe, reliable switching in high-speed automation.

MRI machines, X-ray systems, and defibrillators use pulse transformers to generate the high-voltage pulses needed for imaging coils and tube drivers. Electrical isolation provided by the transformer safeguards both patients and equipment.

Pulse transformers are used in network interfaces (such as Ethernet and DSL) to protect delicate electronics from line surges while maintaining signal integrity and impedance matching. They are also essential in digital communication circuits where precise timing is crucial.

In modern power electronics—including switch-mode power supplies, renewable energy converters, and electric vehicles—pulse transformers enable efficient, isolated switching of high-voltage transistors, which is key to compact and efficient power management

High voltage pulse transformers are used in laboratory environments for material and component testing, as well as in electron beam and plasma physics experiments that require precise, repeatable pulse delivery.

Some industrial processes (like electroconvulsive therapy and certain types of welding) use pulse transformers to generate controlled high-voltage pulses for process initiation or regulation.

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Let Leightner Design Your High Voltage Pulse Transformer Today

With over 50 years of manufacturing and hundreds of thousands of High Voltage Pulse Transformer built to specifications, Leightner can handle any application of your custom High Voltage Pulse Transformer needs. Request a quote to start the manufacturing process today!

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Leightner has over 50 Years of Experience Prototyping, Designing, & Manufacturing Custom Transformers For All Types of Applications

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