From Requirements to Delivery: Leyu Industrial Power Supply OEM/ODM Custom Development

What is power supply OEM/ODM customization?

Before diving into the process, let us clarify two key concepts:

OEM (Original Equipment Manufacturing): 

The client provides complete design blueprints and technical specifications; the factory manufactures the product according to these designs and delivers finished goods that meet the requirements.

ODM (Original Design Manufacturing): 

The client outlines functional requirements, performance metrics, and cost targets; the factory handles the entire process—ranging from conceptual design, component selection, and hardware/software development to structural design, testing, validation, and mass production—ultimately delivering a product ready for market launch.

Leyu Electric possesses an in-house R&D team and a comprehensive production system. We offer both OEM and ODM service models, providing the flexibility to meet a wide range of needs—from "manufacturing to print" to "development from scratch."

Leyu’s Six-Step OEM/ODM Development Process

Step 1: Requirements Alignment and Feasibility Assessment

A successful custom power supply project typically begins with a rigorous and comprehensive analysis of requirements.

During this stage, Leyu’s engineering team engages in in-depth discussions with the client to confirm key information, including:

Electrical Parameters: Input voltage range, output voltage/current, maximum output power, efficiency requirements, ripple and noise specifications, etc.

Mechanical Structure: Physical dimensions, mounting method (DIN rail, wall-mount, embedded), interface types, ingress protection (IP) ratings, etc.

Certification Requirements: Safety certifications required for the target market, such as CCC, UL, CE, FCC, PSE, etc.

Application Scenarios: The end-use environment—such as industrial, medical, or telecommunications equipment, or new energy systems—as requirements for EMC performance, safety levels, and reliability vary significantly across these contexts.

Special Requirements: Needs for N+1 redundancy/parallel operation or current sharing; requirements for special environments (high altitude, high humidity, salt spray, explosion-proof); and software functions such as communication protocols, remote monitoring, or adjustable voltage/current.

Mass Production Planning: Estimated annual shipment volume, delivery lead times, and cost targets.

Once information gathering is complete, Leyu’s R&D team conducts a technical feasibility assessment and produces a project outline. This includes recommendations on topology selection and key components, as well as estimates for the development timeline and budget.

The core objective of this stage is to quantify requirements. Vague requirements entering the subsequent development phase often lead to repeated revisions and disagreements. Drawing on extensive development experience across product lines—including industrial switching power supplies, DIN-rail power supplies, power modules, charging modules, and inverters—Leyu is able to rapidly and accurately assess the feasibility of diverse customization requests.

Step 2: Solution Design and Key Component Selection

Following a successful feasibility assessment, the project enters the technical solution design phase. This stage involves the highest concentration of technical decision-making throughout the entire development cycle.

Circuit Architecture Design

Key Component Selection

Simulation and Verification

Step 3: Hardware and Mechanical Design

Upon confirmation of the solution, the project proceeds to the detailed engineering design phase.


Schematic Design
This stage involves finalizing component selection and circuit connections, with a focus on achieving high efficiency and low ripple. Particular attention is paid to the gate drive circuitry for switching devices, feedback network stability, and power-stage grounding layout. Upon completion, Design Rule Checks (DRC) and Electrical Rule Checks (ERC) are performed.


PCB Design
This is a technically demanding stage. The layout and routing of the power supply PCB directly influence the product's electromagnetic compatibility (EMC) and thermal performance. Leyu engineers strictly control key design aspects, such as isolation between power and control stages, minimization of power loop areas, single-point grounding connections between control and power grounds, and the routing of sampling and feedback signals away from nodes with high di/dt or dv/dt interference.


Structural Design
Product housing design—covering dimensions, mounting hole locations, terminal types, and thermal management structures—proceeds concurrently. Leyu can customize designs based on CAD drawings provided by the client. Additionally, the structural design phase includes thermal simulations or testing, verification of ingress protection (IP) ratings, and the incorporation of "poka-yoke" (error-proofing) features, such as mechanisms to prevent reverse insertion or incorrect assembly of terminals.


A Design for Manufacturability (DFM) review is mandatory at this stage. This involves evaluating the design from a manufacturing perspective to ensure excellent processability and to lay the groundwork for subsequent mass production.

Step 4: Sample Fabrication and Engineering Verification

Once the design drawings are finalized, the project moves to the sample development phase.


Leyu’s engineering team handles PCB fabrication, SMT assembly, component mounting, and preliminary functional testing based on the design specifications. Upon completion of sample fabrication, comprehensive Engineering Verification Testing (EVT) is conducted:


Item-by-item functional performance testing


Performance verification under ambient and high-temperature conditions


Ripple and noise testing


Protection function testing (over-voltage, over-current, over-temperature, short-circuit, etc.)


Verification of assembly clearances and thermal management


All EVT prototypes must pass a 100% full-load burn-in test to verify long-term operational stability. After receiving the EVT prototypes, clients are encouraged to conduct verification in actual application environments—such as burn-in tests and operational sequence simulations—to identify potential risks associated with mass production early on.


Leyu products are manufactured in strict accordance with national standards, ensuring stable performance and reliable quality. For projects requiring specific certifications, pre-testing for safety and EMC compliance is initiated during this phase; this allows for the early detection and resolution of potential issues, thereby saving time for the formal certification process.

Step 5: Pilot Production Verification and Design Finalization

After sample verification is successful, the project proceeds to the small-batch pilot production stage (DVT/PVT).

Leyu conducts small-batch pilot production—typically involving 50 to 200 units—using formal production jigs, stencils, and Standard Operating Procedures (SOPs) to comprehensively verify production line consistency and process stability.

Key areas monitored during pilot production include:

Soldering quality

Thermal dissipation performance

Withstand voltage testing

End-to-end quality control: IQC (Incoming Quality Control) → IPQC (In-Process Quality Control) → FQC (Final Quality Control)

Simultaneously, key parameters are locked in and batch consistency is ensured through methods such as CPK/PPK process capability analysis, SPC (Statistical Process Control) monitoring of critical processes, and reflow oven profile verification.

Upon completion of pilot production, the engineering team issues a summary report, tracing any identified issues back to the design source for rectification. Subsequently, all technical documentation is frozen, the Bill of Materials (BOM) is locked, and process parameters are finalized; any subsequent changes must undergo the formal Engineering Change (EC) process.

Formal applications for product certification are submitted during this stage. Because pre-testing was initiated during the EVT phase, the risk of requiring rectifications during the certification process is significantly reduced. Obtaining safety certifications for power supply products (such as UL, CE, CCC, etc.) typically takes several months; Leyu collaborates with clients to formulate certification plans, ensuring that market launch schedules are not delayed.

Step 6: Mass Production and Continuous Delivery

Once the design is finalized, the project enters the mass production phase.

Leyu’s manufacturing operations are largely automated, featuring advanced production processes and comprehensive testing equipment, ensuring ample production capacity and rapid delivery. Key controls during the mass production phase include:

Raw Material Locking: Bulk procurement of core materials to ensure supply stability.

Production Scheduling: Rational planning of production schedules based on order volumes.

Burn-in Testing: 100% of units undergo full-load burn-in testing for 4–8 hours.

Comprehensive Final Inspection: 100% inspection of finished products to ensure compliance with standards.

The launch of mass production does not mark the end of the partnership. During the continuous delivery phase, Leyu implements a batch traceability mechanism; each batch undergoes sampling—at a rate of 10%—under extreme conditions such as high temperatures, low-voltage input, and full loads to verify batch consistency. Simultaneously, the process stability of key manufacturing steps is continuously monitored to ensure product consistency and long-term quality.

For clients requiring brand customization, Leyu offers comprehensive branding and private-label services—including silk-screening of client logos, custom manuals, and branded packaging—to help enhance brand recognition.

Why Choose Leyu?

Over Two Decades of Expertise

Established in 2005, Leyu Electric is a specialized high-tech enterprise integrating R&D, manufacturing, sales, and technical services, with over 20 years of deep experience in the power supply industry.

Full-Chain Service Capabilities

Covering everything from requirements analysis and solution design to prototype development and mass production delivery, Leyu employs an integrated business model to provide customers with one-stop, customized power supply solutions.

Comprehensive Quality System

The company utilizes advanced manufacturing processes and state-of-the-art testing equipment. Products are manufactured in strict accordance with national standards, ensuring stable performance and reliable quality, and have obtained numerous domestic and international safety certifications.

Proven Global Market Presence

Leyu’s products are exported to Southeast Asia, the Middle East, the Americas, Africa, Europe, and beyond, earning the trust of customers worldwide.

Flexible Customization Capabilities

From switching power supplies to inverters, and from modifying standard products to fully customized development, Leyu supports customization across all parameters—including wide-range voltage input, multi-channel output, special dimensions, specific certifications, private labeling, and more.

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