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IRON CHROME COBALT (FECRCO) – A CASE STUDY

IRON CHROME COBALT (FECRCO) – A CASE STUDY

by | May 20, 2025 | Allstar Magnetics News, Industry News

IRON CHROME COBALT (FECRCO):

Explore the Tone-Shaping Potential of FeCrCo for
Guitar Pickups

Iron Chrome Cobalt (FeCrCo) is a cobalt-chromium-based magnetic alloy originally developed as a replacement for CuNiFe. It is now gaining popularity in the audio and guitar industries as a high-performance alternative to AlNiCo—delivering vintage tone with modern manufacturability.

Key Properties

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Property
 Value Benefit
 Value B
High Remanence (Br)
 Warm tonal output, comparable to AlNiCo pickups
Low Coercivity (Hc)
 Easily magnetized and shaped for precision field control
High Temp Resistance
 Stable performance across a wide range of temperatures
Low Temp Coefficient
 Predictable behavior under changing conditions
Corrosion Resistance
 No coating required—ideal for long-term durability
Manufacturing Advantages:
  • Ductile and Formable: Can be rolled, stamped, and bent before heat treatment
  • Machinable: Easier to process than traditional AlNiCo or rare earth alloys
  • Thin Strip Capability: Can be formed into very thin strips for compact designs
  • No Post-Coating Required: Simplifies production and reduces cost
Available Forms:
  • Isotropic: Multi-directional magnetization
  • Anisotropic: Enhanced directional magnetic performance
Recommended Applications
  • Magnetic pole pieces and slugs for guitar pickups
  • Magnetic cores for custom audio transducers
  • Prototype pickup designs requiring material flexibility and tonal warmth
Why Choose FeCrCo?
FeCrCo offers the tonal character of classic materials with the manufacturability modern pickup designers need. It bridges the gap between vintage warmth and production flexibility—making it an excellent choice for builders and engineers in the audio space.
Typical Magnetic Performance Range for Cast FeCrCo

FeCrCo12/4 (referred to as FeCrCo1) and FeCrCo44/4 (referred to as FeCrCo5) are the two most commonly used Iron Chromium Cobalt materials. The other materials are available but may have a larger min order quantity.

Contact Us
Looking for a material that delivers vintage tone with modern manufacturability? Contact Allstar Magnetics—your trusted partner for FeCrCo prototyping and full-scale production, specializing in magnetic solutions for audio and guitar applications..
MODULAR & STACKABLE U-CORES – A CASE STUDY

MODULAR & STACKABLE U-CORES – A CASE STUDY

by | May 19, 2025 | Allstar Magnetics News, Case Study, Industry News

MODULAR & STACKABLE U-CORES:
PRECISION & EFFICIENCY FOR MODERN APPLICATIONS

At Allstar Magnetics, we specialize in custom magnetic solutions tailored to meet the needs of industries requiring high-performance magnetic assemblies. Our Modular & Stackable U-Core configuration is designed for efficiency, flexibility, and cost-effectiveness, serving a variety of applications where superior electromagnetic performance is required.

System Benefits:

  • Standard design with multiple
    configuration options
  • Lower cost compared to custom tooling
    or machining
  • Parts in stock for immediate assembly
    and shipment
  • Cost-effective prototyping for quick
    design validation
  • Bobbins available (as shown in the image)
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Key Applications of Modular & Stackable U-Cores:

  1. High Voltage Transformers: Efficient voltage conversion and regulation for industrial and commercial power supplies.
  2. High-Frequency (HF) Filters Reduces noise and unwanted frequencies in power electronics and RF applications.
  3. Security Detection Equipment: Aviation security explosive detection system (EDS).
  4. Renewable Energy Systems: Applied in power inverters for solar and wind energy conversion.
From Concept to Manufacture: A Customized Approach

Since 1989, we have specialized in the development and manufacturing of custom magnetic solutions utilizing neodymium magnets and stainless steel. Our expertise lies in building complex magnet assemblies and systems.

We utilize custom CNC tapping and specialty-grade steel backings to ensure structural integrity. Whether it’s flat or U-channel linear magnetic designs, we refine concepts into manufacturable designs. We also consider:

  • Temperature and environmental effects on manufacturing processes
  • Adhesive specifications for varying environmental conditions such as humidity, heat, and outgassing
  • The impact of these factors on machining tolerances

Our proprietary process is not only cost-effective but also highly repeatable. Our unique approach allows us to provide customers with custom-built and staged linear motor tracks tailored for highly accurate motion control and positioning systems on demand.

Corner
 
Part number: B67410-A0250-X187 N87 material
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Part number: B67410-A0249-X187 N87 material
Leg
 
Part number: B62110-A6018-X087 N87 material
THE POWER OF AS9100 CERTIFICATION – A CASE STUDY

THE POWER OF AS9100 CERTIFICATION – A CASE STUDY

by | Mar 11, 2025 | Allstar Magnetics News, Case Study

THE POWER OF AS9100 CERTIFICATION

Modernizing for Success: How AS9100 Certification Transformed Aerospace Manufacturing and Quality Standards

Client: An OEM supplier for power generation and distribution, motion control, RF amplifiers, data acquisition, and cockpit instruments primarily for the aerospace industry.

Project Overview: Our client has been manufacturing magnetic components for critical aerospace applications for years. Their products were grandfathered into existing systems from companies without aerospace certification. However, as the industry has moved to a point where AS9100 certification is now required, the urgency to upgrade has become critical. Both existing programs and new projects within the modern aerospace industry were now at risk. To stay competitive and future-proof its operations, this company needed to transition to a fully AS9100-certified manufacturing environment.

Allstar’s Approach: Allstar Magnetics partnered with our client to modernize their production and certification processes. By leveraging our deep expertise in aerospace compliance and precision manufacturing, we guided them through the transition from standard certification to AS9100 compliance. Over 50 unique parts underwent a complete NPI approval process within a compressed timeframe, ensuring no interruptions to their existing commitments and deliveries. This transformation not only improved their operational standards but also strengthened their position as a competitor in the aerospace market.

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Key aspects of the project included:
 

  1. Comprehensive Product Redesign: Developed drawing packages inclusive of BOM/Spec for over 50 unique products to AS9100 certification standards.
  2. Certification Transition: Migrated production from a legacy framework to a fully compliant AS9100-certified environment.
  3. Seamless Manufacturing & Distribution: Ensured all products manufactured under AS9100 compliance could be seamlessl integrated into aerospace supply chains.
  4. End-to-end Support: Provided engineering, prototyping, and production services with the highest level of certification.

Results:
By partnering with Allstar Magnetics, the company successfully transitioned to an AS9100-certified operation. This upgrade expanded their market opportunities, allowing them to bid on higher-value aerospace projects that require strict compliance. It also facilitated better communication of compliance with existing customers. Their newly modernized production process guarantees consistency, quality, and reliability—key factors in maintaining competitiveness in the aerospace industry.

Conclusion:
Today, every product manufactured by this division is produced in an AS-certified environment, giving its customers confidence in the quality and compliance of their end-use components. For aerospace manufacturers looking to elevate their certification and improve competitiveness, Allstar Magnetics offers the expertise and support necessary to achieve world-class standards.

lidar technology – a case study

lidar technology – a case study

by | Jan 14, 2025 | Allstar Magnetics News, Case Study, Industry News

LiDAR TECHNOLOGY
Client: New technology developer for LiDAR applications

Project Overview: The client required a complex milled ferrite and wound wire set for their LiDAR application, designed to allow data and power to move independently without interference. While theoretically feasible at the prototype level, no attempt at volume manufacturing had succeeded due to material and winding complexities. Prior efforts had failed, resulting in critical delays for the client’s product development. Allstar Magnetics partnered with the client to overcome these challenges, leveraging their expertise in CNC milling, winding, and material development to deliver an innovative solution.

LiDAR TECHNOLOGY

Allstar’s Approach: Allstar Magnetics devised a comprehensive manufacturing process to address the project’s unique demands. From optimizing CNC milling parameters to developing a robust winding and gluing process, the team ensured that all components met stringent performance specifications. A 24/5 production strategy enabled consistent high-volume output, while innovative packaging solutions facilitated seamless assembly for the client’s end-use.

Client Testimonial: “Allstar Magnetics’ ability to combine material expertise with advanced CNC milling and winding techniques was the key to overcoming the challenges we faced. Their innovative approach and commitment to quality allowed us to move from prototypes to full-scale production, exceeding our expectations and enabling the success of our LiDAR program.”

Conclusion: Comprehensive magnetic solutions, all in one place. Allstarmagnetics.com Through a combination of CNC milling, material expertise, and precision manufacturing techniques, Allstar Magnetics enabled the client to achieve what had previously been impossible: high-volume production of a complex milled ferrite and wound wire set. This case study underscores the value of Allstar’s holistic approach to solving intricate manufacturing challenges, positioning their client for long-term success in the rapidly evolving LiDAR technology sector.

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Key Aspects of the Project:

  1. Research & Material Development: Allstar conducted extensive research to understand the materials’ specific properties and challenges, laying the groundwork for a reliable manufacturing process.
  2. CNC Milling: The team established optimal cutting tools and RPM levels to precisely mill the specialty ferrite components, implementing high-efficiency placement arrays for volume production.
  3. Prototype Conversion to Volume Production: What began as a prototype was rapidly scaled into a repeatable, high-volume manufacturing process.
  4. Winding and Gluing: A refined winding and gluing process minimized breakage and maintained precise inductance specifications.
  5. Testing: 100% AQL testing ensured compliance and reliability, with all data communicated to the client in advance.
  6. Packaging: Allstar designed new packaging materials and layouts to ensure safe transportation and immediate usability upon delivery.

Results: Allstar Magnetics delivered a manufacturing solution that allowed the client to:

  • Ramp up production 10x within 30 days.
  • Eliminate nearly all in field failures associated with the milled and wound components.
  • Secure larger contracts and advance their program from concept to growth phase.
  • Achieve exceptional reliability and durability in the critical ferrite and winding components, ensuring the success of their LiDAR product.
LiDAR TECHNOLOGY