IEC 60601 RF Generator PCB

Project Overview

We are developing a next-generation vessel sealing generator similar to Valleylab LS10 / Voyant RF sealing systems.
The device is a medical-grade, high-frequency RF surgical generator operating around 400 kHz, delivering controlled energy to surgical instruments for vessel sealing.

We are looking for an experienced PCB Design Engineer with medical device background and strong familiarity with:

IEC 60601-1 safety requirements (creepage, clearance, MOPP, isolation)

IEC 60601-1-2 EMC design practices

High-frequency power electronics (200–500 kHz)

Full-bridge power stages, resonant tanks, HF isolation transformers

Mixed-signal PCB layout (DSP, MCU, analog sensing circuits)

This is not a basic PCB job; we need someone comfortable designing medical-grade, safe, isolated, low-noise, high-power RF systems.

Work Scope

You will design the full PCB based on our finalized block diagram, schematics, and BOM, including:

1. Power & RF Section

48 V DC bus (medical SMPS – SL Power MINT series)

Phase-shift full-bridge MOSFET stage

350–450 kHz resonant tank (Lr + Cr)

Custom HF transformer (isolation barrier)

RF output filtering

Snubbers, high-di/dt loop optimization

Thermal and creepage/clearance constraints

2. Sensing & Safety Section

Dual independent voltage & current sensing chains

Capacitive voltage dividers

Rogowski/CT current sensors

Analog multiplier chain (AD633)

VMAD / IMAD safety circuits

Isolation implementation per medical standards

3. Control Electronics

Host MCU (STM32H7 or similar)

DSP (TI C2000 class) for RF control

USB-UART, fan control, audio output, LEDs, footswitch/hand switch isolation

4. PCB Layout Requirements

Multi-layer PCB (likely 4–6 layers)

Strict isolation barrier implementation (≥ 8 mm creepage/clearance)

Controlled return paths for HF current

Dedicated ground planes for:

RF high-current domain

Analog sensing domain

Digital MCU/DSP domain

Minimizing coupling between RF and sensitive analog nets

Medical-grade EMI/EMC considerations

Proper thermal management of MOSFETs + drivers

Deliverables

Full Altium Designer project

Clean and readable schematic (hierarchical design)

PCB layout based on:

Isolation rules

HF switching guidelines

EMC best practices

Manufacturing files:

Gerbers

Drill files

Assembly drawings

Pick & place

Fabrication notes

Optional: 3D model and thermal recommendations

Required Experience
Mandatory

Proven experience designing medical electronic devices

Understanding of IEC 60601-1 and 60601-1-2 requirements

Experience with power electronics (100–500 W)

Previous work on high-frequency switching (≥200 kHz)

Isolation design: MOPP, creepage/clearance, safety barriers

Mixed-signal PCB layout expertise

Preferred

Experience with RF surgical generators / ESUs

Experience with TI C2000 or STM32H7 boards

Familiarity with resonant converters, HF transformers

Experience passing EMC/ESD/Fast Transient tests

What We Provide

Block diagrams

General BOM

Electrical requirements

Mechanical constraints

Transformer specifications

Consulting availability during the project