This paper presents the design and development of a transformer isolated high-power dc-dc converter. There are several design issues and challenges. In this paper, we focus on three major issues in high-power dc-dc converters. 1) An energy recovery passive snubber circuit and the selection of pulsewidth modulation control methods are first introduced to reduce the voltage spike and power loss across switching devices. 2) Interleaved winding method is then employed to reduce proximity effect in the transformer winding. 3) The voltage oscillation problem in the secondary rectifier diode is addressed, and solutions are provided.