Serving the Railroad Industry
Custom Magnetic Components for Locomotives and Rail Systems
The railroad industry runs on reliability. A locomotive idling on a siding, a signal system failing at a crossing or a passenger car losing lights and climate control all have one thing in common: somewhere down the line, a magnetic component stopped working. Coils, transformers and chokes are the quiet workhorses behind everything from engine ignition to onboard power distribution. When they fail, trains stop.
For over 50 years, Custom Magnetics has designed and manufactured custom coils and transformers for the most demanding applications. Our components are built to withstand the vibration, temperature swings and constant duty cycles that railroad equipment faces every day. From mainline locomotives to light rail transit systems, we supply the magnetic components that keep trains moving and infrastructure operating.
Ignition Coils for Locomotive Engines
Diesel-electric locomotives depend on ignition systems with high energy to start and control their prime movers. This requires the ignition coil to deliver consistent spark energy across thousands of hours of operation while standing up to temperatures under the good and constant vibration, which is why off-the-shelf ignition coils are not built for this duty cycle.
Custom Magnetics designs locomotive ignition coils to match the specific voltage, current and dwell requirements of each engine platform. We work with your engineers to determine the correct turns ratio, primary resistance and secondary voltage output. Our coils are potted and sealed to resist moisture, oil and dirt ingress. Terminal configurations, mounting brackets and lead lengths are all built to your specification. Whether you need coils for new production locomotives or replacement units for legacy fleets, we can deliver.
Chokes and Inductors for Filtering and Noise Suppression
Railroad electrical systems generate significant electrical noise from traction motors, inverters and switching power supplies, which can interfere with sensitive control systems and communication equipment, but chokes and inductors suppress this noise by blocking high-frequency interference while allowing desired signals to pass.
We manufacture common-mode chokes, differential-mode chokes and custom inductors for railroad power supplies and control circuits. Core materials are selected for high saturation current and low core loss. Winding configurations are optimized for the specific impedance and frequency response your application requires.
Power Transformers for Onboard Locomotive & Rail Car Systems
A modern locomotive or passenger rail car contains dozens of electrical systems that require stable, conditioned power, including lighting, HVAC, battery charging, control electronics and passenger information systems, all of which need transformers to step voltage up or down, isolate circuits and filter noise.
Custom Magnetics builds power transformers for railroad applications in a range of sizes and configurations, with laminated and toroidal designs that deliver efficient power conversion and minimal heat generation, plus R-core transformers for space-constrained installations that combine high efficiency with a compact footprint. All transformers are wound and assembled in our ISO 9001-certified facility with testing performed to your specified tolerances.
Signal and Crossing System Components
Railroad signal systems and grade crossing controls operate 24 hours a day, 365 days a year. A failed transformer or coil in a signal bungalow can shut down an entire subdivision. These systems require components that are sealed against moisture, resistant to temperature extremes and built for decades of continuous operation.
Custom Magnetics produces isolation transformers, coupling transformers and gate coils for signal and crossing systems. Our designs prioritize long-term reliability over low cost. Encapsulation and potting protect against humidity and contamination. Terminal blocks and lead configurations are designed for easy field installation and replacement.
Reverse Engineering for Obsolete Railroad Components
One of the biggest challenges facing railroad maintenance departments is sourcing replacement parts for older locomotives and systems. Original manufacturers discontinue components. Suppliers go out of business. Blueprints get lost. Custom Magnetics solves this problem with reverse engineering services.
Send us your obsolete coil, transformer or choke. We will analyze its construction, measure its electrical characteristics and document its mechanical dimensions. From there, we produce a new component that matches the original form, fit and function. No redesign needed. No chasing outdated part numbers. Just a direct replacement that keeps your equipment running.
Why Railroads Choose Custom Magnetics
- Experience: Over 50 years designing and manufacturing magnetic components for demanding industries.
- ISO 9001 Certification: Consistent quality and documented processes.
- Full-Service Capabilities: From initial design through prototyping to production runs.
- Reverse Engineering: We build replacements for obsolete components when original suppliers are gone.
- Domestic Manufacturing: All products built in our North Manchester, Indiana facility.
Partner with Custom Magnetics for Your Railroad Component Needs
Whether you need ignition coils for a fleet of locomotives, power transformers for passenger rail cars or replacement chokes for signal systems, Custom Magnetics has the engineering expertise and manufacturing capability to deliver.
Contact our team to discuss your railroad application or request a quote for custom magnetic railroad components.