Rugged High-Performance DC-DC Converters Design
Budget: $750 – $1,500 AUD
DC-DC Converters Project
Project Overview:
I am building a new Australian brand focused on creating the world’s best DC-DC converters in efficiency, reliability, and thermal & EMI performance. Our goal is to deliver rugged, high-performance converters for 4WDs, caravans, off-grid vehicles, and heavy-duty rigs.
I am looking for an experienced electronics engineer to design three DC-DC converter models. The deliverables will include schematics, PCB layout, BOM, and simulation files. I will handle prototyping, testing, and enclosures.
________________________________________
Project Goals / Business Values
• Build the highest-efficiency, most reliable DC-DC converters
• Ensure excellent thermal management and low EMI
• Focus on rugged (IP67+), safe designs suitable for automotive/off-grid applications
• Deliver designs that can serve as the benchmark for world-class converters
________________________________________
Product Models
1️⃣ Mini 5
• Input → Output: 12 V → 5 V
• Current: 5 A
• Use Case: USB devices, IoT electronics, small accessories in vehicles and vans
• Objective: Compact, high-efficiency, low-heat converter with minimal ripple for small electronics
2️⃣ Core 30
• Input → Output: 24 V → 12 V
• Current: 30 A
• Use Case: Mid-range 4WDs, campervans, solar battery setups (step-down only)
• Objective: Rugged mid-range converter that handles high currents efficiently, with superior thermal and EMI design
3️⃣ Alpha 50
• Input → Output: 12/24 V → 12/24 V (auto-detection buck-boost)
• Current: 50 A
• Use Case: Heavy-duty caravans, tradie rigs, high-power off-grid systems
• Objective: High-current, dual-voltage converter capable of automatically switching between buck and boost modes. Must maintain stable voltage, high efficiency, and robust thermal management
________________________________________
Deliverables for Freelancer
• Schematics for all three models
• PCB layout ready for manufacturing (Gerbers + drill files)
• Bill of Materials (BOM) with recommended components
• Simulation files (efficiency, thermal, voltage ripple, EMI)
• Notes on cooling, high-current PCB layout, Enclosure Selection and EMI suppression
________________________________________
Technical Requirements
• Focus on DC-DC step-down/step-up
• Use proven buck, boost, or buck-boost topologies
• Auto buck-boost for Alpha 50 must be seamless and reliable
• Target rugged, automotive/off-grid standard designs
• High efficiency, low heat, and minimal EMI are priorities
________________________________________
Why Join This Project
• You will work on a challenging, high-value engineering project
• Opportunity to help build a brand with a world-class focus on efficiency, reliability, and ruggedness
• Successful collaboration may lead to future projects on higher-power converters or advanced designs
________________________________________
Interested engineers should:
• Provide examples of past DC-DC converter designs
• Confirm capability to deliver schematics, PCB layouts, BOMs, and simulations
• Share preliminary ideas for high-efficiency, thermal-aware, low-EMI designs
Project Overview:
I am building a new Australian brand focused on creating the world’s best DC-DC converters in efficiency, reliability, and thermal & EMI performance. Our goal is to deliver rugged, high-performance converters for 4WDs, caravans, off-grid vehicles, and heavy-duty rigs.
I am looking for an experienced electronics engineer to design three DC-DC converter models. The deliverables will include schematics, PCB layout, BOM, and simulation files. I will handle prototyping, testing, and enclosures.
________________________________________
Project Goals / Business Values
• Build the highest-efficiency, most reliable DC-DC converters
• Ensure excellent thermal management and low EMI
• Focus on rugged (IP67+), safe designs suitable for automotive/off-grid applications
• Deliver designs that can serve as the benchmark for world-class converters
________________________________________
Product Models
1️⃣ Mini 5
• Input → Output: 12 V → 5 V
• Current: 5 A
• Use Case: USB devices, IoT electronics, small accessories in vehicles and vans
• Objective: Compact, high-efficiency, low-heat converter with minimal ripple for small electronics
2️⃣ Core 30
• Input → Output: 24 V → 12 V
• Current: 30 A
• Use Case: Mid-range 4WDs, campervans, solar battery setups (step-down only)
• Objective: Rugged mid-range converter that handles high currents efficiently, with superior thermal and EMI design
3️⃣ Alpha 50
• Input → Output: 12/24 V → 12/24 V (auto-detection buck-boost)
• Current: 50 A
• Use Case: Heavy-duty caravans, tradie rigs, high-power off-grid systems
• Objective: High-current, dual-voltage converter capable of automatically switching between buck and boost modes. Must maintain stable voltage, high efficiency, and robust thermal management
________________________________________
Deliverables for Freelancer
• Schematics for all three models
• PCB layout ready for manufacturing (Gerbers + drill files)
• Bill of Materials (BOM) with recommended components
• Simulation files (efficiency, thermal, voltage ripple, EMI)
• Notes on cooling, high-current PCB layout, Enclosure Selection and EMI suppression
________________________________________
Technical Requirements
• Focus on DC-DC step-down/step-up
• Use proven buck, boost, or buck-boost topologies
• Auto buck-boost for Alpha 50 must be seamless and reliable
• Target rugged, automotive/off-grid standard designs
• High efficiency, low heat, and minimal EMI are priorities
________________________________________
Why Join This Project
• You will work on a challenging, high-value engineering project
• Opportunity to help build a brand with a world-class focus on efficiency, reliability, and ruggedness
• Successful collaboration may lead to future projects on higher-power converters or advanced designs
________________________________________
Interested engineers should:
• Provide examples of past DC-DC converter designs
• Confirm capability to deliver schematics, PCB layouts, BOMs, and simulations
• Share preliminary ideas for high-efficiency, thermal-aware, low-EMI designs