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This paper presents various techniques to achieve high efficiency for the bidirectional Cascaded-Buck-Boost converter. This converter has the features of low voltage across the switches and positive output voltage. The objective of this paper is to optimize the magnetics design to reduce the total losses in a low power non-isolated DC-DC circuit. A rigorous loss model with component nonlinearities is developed to determine the power loss distribution. It is validated by simulations and experiments. Based on the results of the power loss analysis and due to the low inductor profile and high efficiency target, nanocrystalline material will be the best candidate. Therefore, a new small volume low profile planar-nanocrystalline inductor is designed. Various deep de sign aspects for core and copper are discussed. The Finite-Element-Analysis (FEA) method is used to examine and visualize the inductor design. By implementing the planar-nanocrystalline inductor, a California Energy Commission (CEC) weighted efficiency of 99.05% for the buck mode and 98.98% for the boost mode are achieved with a peak efficiency of 99.24% and 99.21%, respectively. [ABSTRACT FROM AUTHOR]