While following this thread, I saw a couple of people mention R-cores.
Would they not be better?
I'd once seen one and thought it was some eccentric variant on a toroid
that someone made so they could mount it where their design once called for
a chassis mounted E/I type, or had some other odd space restriction. I was
so wrong.
From what I saw via Google once I'd seen the name 'R-core', I see that easy
fitting of split bobbins directly round the straight long sections allows
either a commercial firm OR a hobbyist to not only build their windings
quickly and easily, but to modify them, as an assembled bobbin can rotate
freely if wanted. Electrical isolation between windings can be better than
in a toroidal type, which could be important for use in a medical device.
The efficiency is good, and the flux well-contained, and they'd probably
run as quietly as toroidals. Waste heat can escape from them more
efficiently that either E/I types or toroidals. I'm surprised they aren't
much more widespread than toroidals.