Compact Flyback SMPS Design

I need a seasoned power-electronics engineer to take my concept for a small, isolated flyback switching power supply and turn it into a production-ready design for a consumer-electronics product. The supply must accept 230 V AC nominal but remain stable across the full universal range of 85–265 V AC. On the secondary side I want three rails—12 V, 5 V, and 3.3 V DC—sharing roughly 3–4 W total. Exact current splits can wait until you help me finalise the power budget.

Compact size is the top priority, so I expect smart component selection, tight transformer design, and a PCB layout that keeps both footprint and height to an absolute minimum while still meeting creepage, clearance, and EMI/EMC requirements. Although efficiency and low standby losses matter (this will run continuously and must stay cool), I will trade fractional points of efficiency for measurable volume savings if needed.

I have no brand or model bias for the controller IC, MOSFET, transformer core, or magnetics—please propose parts you trust for cost-effective mass production. Keep the bill of materials realistic for high-volume sourcing.

Deliverables I’m expecting:
• Complete schematic with calculated component values
• Optimised PCB layout (Gerbers + native files) ready for manufacturing
• Transformer specification and winding guide suitable for automated production
• Annotated bill of materials with multiple sourcing options where possible
• Simulation or bench data demonstrating regulation, efficiency, standby draw, ripple, and thermal performance
• Brief design report outlining safety compliance (reinforced isolation, surge, conducted and radiated EMI strategy)

If you have handheld-electronics experience and can squeeze every cubic millimetre out of a flyback while keeping it safe and affordable, let’s discuss your approach and timeline.