10 kV HV Supply Module Design

I’m building an air-purifier stage that needs a reliable 10 kV DC source and I want a complete, ready-to-build design package. The module has to integrate its own high-frequency transformer, rectification, and smoothing capacitors—all engineered together as a single high-voltage block rather than loose sub-assemblies.

Target output is a clean, stable 10 kV with low ripple at the few-milliamp level typical for corona discharge plates. Once we start I’ll share the envelope drawing so you can shape the board and potting arrangement around my custom dimensions; space is limited, so thermal and creepage planning are critical.

What I expect from you:
• Schematic with design calculations (turns ratio, core selection, snubbers, insulation clearances).
• Full bill of materials using components that are globally available.
• PCB or modular layout files (KiCad, Altium, or equivalent) sized to the envelope I’ll provide.
• Mechanical notes on winding, potting, and mounting so the transformer and capacitors stay robust under continuous operation.
• Safety and test procedure for verifying output, ripple, and insulation integrity before I commit to production.

Experience with high-voltage magnetics, corona or ozone generators, and compact power supplies will help you move quickly. If you can simulate in LTspice or similar before layout, even better. Looking forward to seeing how you’d tackle the challenge.