As part of the DEEP PPU consortium, FRAZA has played a central role in developing cutting-edge magnetic components for the Radio Frequency Generator (RFG) and filter units. These components are essential for achieving the project’s goal: a fully integrated, high-efficiency power processing unit capable of supporting next-generation electric propulsion systems.
From State-of-the-Art Review to Space-Ready Designs
The development process followed four key phases:
1. Understanding the Physical Challenges
The FRAZA team analysed not only existing market solutions but also the underlying electromagnetic behaviour under high-frequency, high-current conditions.
The goals were clear:
- Maximise current-carrying capability
- Minimise high-frequency losses (skin, proximity and fringing effects)
- Eliminate longitudinal current
- Improve thermal performance through cooling-friendly geometries
2. Simulation and Co-Design with UPM
UPM investigated numerous electronic architectures for the RFG. For each candidate, FRAZA calculated and simulated corresponding magnetic components—evaluating volume, mass, losses, and suitability.
This iterative process ensured optimal system design and full alignment between magnetics, control electronics, and the system-level design.
3. Prototyping and Testing
Once the optimal architecture was selected, FRAZA developed dedicated production tools and manufactured seven custom magnetic components:
- Isolation transformer
- Zero-voltage-switching (ZVS) inductor
- Buck inductor
- Zero-current detection sensor
- Compensation network inductor
- Filter inductor
- Linear conductor magnetics
Each prototype was extensively tested in-house before being integrated and tested at UPM.
4. Preparing for Space Qualification
All designs were adapted to meet stringent space requirements, including compliance with MIL-STD-981 for space-grade magnetics. The manufacturing process was refined throughout prototyping to ensure repeatability and robustness.
Breakthroughs in Magnetic Technology
The new magnetic designs demonstrated remarkable improvements compared to existing space-certified components:
- >90% reduction in mass and volume
- ~90% reduction in losses
- Up to 50% estimated cost reduction
These gains position FRAZA’s magnetics among the most efficient and compact solutions available for high-frequency, high-power space applications.
Ultra-Fast Current Detection
A major innovation resulting from the project was a zero-current detection sensor with a latency as low as 7 nanoseconds, combining exceptional speed with low mass and minimal losses.
Linear Conductor Advancements
FRAZA also investigated the issue of longitudinal currents in flat-conductor structures, producing a 6-metre linear conductor with high resonance frequency damping capabilities to validate the electromagnetic behaviour and improve design rules for long high frequency power links.
Impact Beyond the DEEP PPU Project
Participation in DEEP PPU has had a transformative effect on FRAZA:
- New magnetic technologies were developed and validated
- Designs were adapted for space applications
- Manufacturing processes were improved
- The company gained visibility and recognition within the European space ecosystem
- Collaboration opened pathways into additional sectors
As a result, FRAZA’s magnetic technologies are now expanding into:
- Space propulsion
- Automotive applications
- Industrial high-efficiency drives
This cross-sector adoption supports broader goals of energy efficiency, decarbonisation, and sustainable design – reinforcing FRAZA’s commitment to forward-looking innovation.
A Successful Collaboration with Long-Term Benefits
The DEEP PPU project has enabled FRAZA to push the boundaries of what is possible in magnetic component design for space. Through close collaboration, rigorous engineering, and continuous innovation, the project has laid the foundation for advanced, energy-efficient magnetics that will benefit multiple industries in the years ahead.
FRAZA is proud to contribute to this milestone and to collaborate with such an outstanding consortium of partners.