Well, that took forever. I finally got the custom inductor I was expecting back in September.
This inductor is wound with 2mm x 6mm flatwire and is the max that could be packed into the 20mm high core.
I was waiting for the samples before cutting the board because sometimes what you get in the proposed part drawing isn't what comes out when it's manufactured. In this case, however, the drawing was indeed correct.
I'll cut 5 base boards and begin testing once they come back. The yellow rings around the 3 holes are where the inductor tabs drop in for soldering. They will result in plated through router cuts when manufactured. They are a bit difficult to see in the image but they wrap the two sets of three holes in front of the inductor in the middle.
I've still got a few edits to make.
This is going to be murder to solder. What you can't see in the shot above are exposed conductive sections that will get laser cut sheet copper to improve their conductivity and lower overall loss.
The board shown is 4.5" by 3.0" with some additional connector overhang on each end. There's an obvious fan mount for a 70mm 12V fan to move air over the hot stuff.
The target is to be able to deliver 850 watts at the output and 0.5 - 36.0 volts with a settable upper limit and a PWM control input while reporting output current back via the fan tach pulse mechanism. The regulator board snaps vertically onto the header along the bottom.