Custom CC/CV Boost Converter with Integrated Heatsink

Challenge: High-power boost converter with CC/CV modes for a tight industrial enclosure. Off-the-shelf modules were either too large or couldn't do the firmware-selectable current/voltage profiles the application needed. Solution: Custom switching design with a bent aluminum heatsink that doubles as an EMI shield. The thermal path was the critical constraint; the heatsink geometry keeps junction temps under 85°C at full load in a sealed enclosure. CC/CV crossover handled in firmware with a smooth transition region to avoid oscillation at the mode boundary. Results: Roughly a third the footprint of the commercial module it replaced. The client controls power profiles through a serial interface instead of external pots and comparators.