Design and fabrication of ultralow-cost and portable high-voltage power supply system for electrohydrodynamic applications

Abstract With rapid expansion in electrohydrodynamics for applications like electrohydrodynamic (EHD) drying, electrospraying, and electrospinning, there is need to design low-cost high-voltage power supply (HVPS) system particularly for developing countries. The present study developed an HVPS based on its design, measurement, and control requirements that can be used for EHD applications. Flyback or line output transformer generated high voltage up to ~ 10 kV (peak-to-peak output voltage). Performance of HVPS was evaluated using current–voltage characteristics and power consumption. Maximum peak-to-peak output current obtained was ~ 450 mA under load of ~ 20 MΩ. Active power and apparent power ranged from ~ 9 to ~ 26 W and ~ 11 to ~ 28 VA, respectively. Of two inputs used for controlling output high voltage ( V hv ), namely input voltage ( V in ) and switching frequency ( f sw ), V hv increased with V in and decreased with f sw . Cost (based on bill of materials and engineering work) and weight of HVPS were ~ 9338 INR (~ 42 EUR in 2025) and 2.4 kg, respectively, offering low-cost and portable solution to generate high voltage for EHD applications.