Modern automotive electronics cover everything from in-vehicle infotainment and ADAS to powertrain control and EV charging. For power and e-mobility systems, OEMs and Tier 1s often rely on specialised EMS partners who understand both power electronics and automotive quality expectations.

TPS focuses on power and control electronics within this ecosystem rather than on complete vehicles:

• DC/DC converters for commercial vehicles, off-highway equipment and auxiliary systems.
• On-board charger (OBC) electronics built around reference designs and architectures used across the industry.
• EV charging power modules and cabinets for DC fast charging and depot charging infrastructure.
• Vehicle test and battery test electronics, including power racks, control boards and harnesses for test benches.

We work as an automotive electronics manufacturer in the sense of EMS: manufacturing to your drawings, supporting design-for-manufacturing and introducing products through structured APQP and PPAP flows, rather than designing our own vehicle platforms.

Discover how these capabilities sit inside our broader electronic manufacturing services stack.

DC/DC converters and auxiliary power electronics

For commercial vehicles and off-highway machines, DC/DC converters supply 12 V or 24 V loads from high-voltage traction batteries. TPS manufactures converter PCBAs, custom magnetics and coolers, and assembles them into housings that withstand vibration and thermal cycling.

• High-power PCB assemblies with automotive-grade components, designed for thermal management and creepage/clearance requirements.
• Custom magnetics and busbars wound and machined in-house to match converter topologies and current levels.
• Liquid- or air-cooled mechanics using CNC-machined coolers and heat sinks integrated with the converter module.

Electronics for battery and vehicle test systems

TPS also builds control and power electronics for diagnostic equipment such as battery test benches and vehicle test stands. These systems require precise power control, reliable measurement and extensive wiring between cabinets and DUTs.

• Control and measurement boards for load control, data acquisition and safety interlocks.
• Power racks with AC input, DC outputs, contactors, fuses and measurement modules.
• Cable and harness assemblies built to automotive wiring standards and labelled for quick setup in test labs.

On-board chargers and EV charging power modules

Whether you design an on-board charger (OBC) or contribute power modules to a DC fast charging system, the building blocks are similar: PFC stages, DC/DC converters, filter networks, control boards, magnetics and thermal management.

• OBC and DC/DC converter PCBAs built with wide-bandgap semiconductors, gate-driver circuits and auxiliary supplies derived from your reference designs.
• EV charging power modules around 20–30 kW that can be paralleled inside a charging cabinet, aligning with industry practice for modular chargers.
• Cooling plates and heat sinks machined to interface with power modules, including liquid-cooling channels and mounting features.

When your project involves chargers or power modules, TPS can focus on automotive electronic manufacturing services while you use application notes and design resources from semiconductor vendors to define topologies and control.

For system-level EV charger design, you may also refer to application resources from semiconductor suppliers while TPS ensures manufacturable, repeatable hardware.

Quality system aligned with IATF 16949

IATF 16949 is the global quality management standard for automotive production and relevant service parts, built on ISO 9001 and extended with automotive-specific requirements such as defect prevention and variation reduction.

TPS aligns its automotive electronics manufacturing processes with the expectations of IATF 16949-compliant customers:

• Documented process flows and control plans for each product family and production line.
• PFMEA and risk-based thinking around solder joints, high-power connections, magnetics and cooling interfaces.
• Systematic traceability from PCB serial numbers through component lots, test results and shipping records.

Details of IATF 16949 requirements are published by recognised standards organisations; TPS focuses on implementing manufacturing practices that help you meet these requirements for your own certification.

Automotive electronics manufacturing services at TPS

Our automotive electronic manufacturing services combine electronics assembly with mechanical integration:

• SMT and THT PCBA lines for power and control boards, including AOI, SPI and in-circuit or flying-probe test where appropriate.
• Winding and impregnation of magnetics such as inductors, transformers and common-mode chokes for automotive power stages.
• CNC-machined coolers and sheet-metal parts to integrate converters and OBC electronics into rugged housings and cabinets.
• Cable harness and cabinet wiring for power racks, chargers and vehicle test cabinets, built to automotive wiring standards.
• End-of-line functional tests that check power-up behaviour, protection functions and interface signals before shipment.

You can find a more detailed overview of these modules on our electronic manufacturing services and integration solutions pages.

Early DFM and NPI support

Successful automotive projects start with manufacturable designs. TPS supports NPI with:

• DFM reviews on PCB layout, component selection and mechanical interfaces for DC/DC, OBC and charger modules.
• DFT input to ensure test points, connectors and diagnostic modes are accessible for production and field returns.
• Prototype and DV builds using the same core processes as production, enabling realistic validation and stress testing.

APQP, PPAP and series production

For programmes following APQP and PPAP, TPS provides documentation and build records that integrate with your own systems:

• Process flow diagrams, PFMEA and control plans aligned with APQP phases.
• Initial sample inspection and capability data for key characteristics such as solder joints, torque, insulation resistance and functional parameters.
• PPAP packages that bundle drawings, control plans, test results and traceability information as required by your customers.

This approach helps you qualify TPS as an EMS partner within your IATF 16949 ecosystem while keeping focus on power electronics and e-mobility systems.

Low-volume DC/DC converter for commercial vehicles

A commercial vehicle OEM develops a custom DC/DC converter to power 24 V auxiliaries from a high-voltage traction battery. Annual volumes are moderate, but automotive quality and documentation are mandatory.

• TPS manufactures power and control PCBAs, magnetics, coolers and sheet-metal covers as a single integrated assembly.
• We execute automotive electronics manufacturing under a documented control plan with traceable components and test data.
• Each converter passes end-of-line functional tests and burn-in, generating records that feed into the OEM’s PPAP documentation.

This approach allows the OEM to focus on vehicle integration, while TPS handles the complexities of power electronics manufacturing and test.

DC charging cabinet for e-mobility infrastructure

An infrastructure provider needs modular DC charging cabinets built from 30 kW power modules and controller boards. They supply electrical schematics and power module designs, and look for a partner that can build complete cabinets.

• TPS assembles 20–30 kW EV charging power modules, including PCBAs, magnetics and liquid-cooled plates.
• We integrate modules into cabinets with AC input sections, DC output busbars, control electronics and cable harnesses.
• Cabinets are tested at rated power using load banks before shipment to the customer’s sites.

For charger certification and grid-connection approvals, the infrastructure provider works with their own system integrators and test labs, while TPS continues to deliver stable, repeatable cabinet assemblies.