Sometimes the magnet isn’t the problem—the design is

by Shaunmarie Gutbezahl | Dec 16, 2025 | Newsletters

December 2025: Issue 5

Welcome to Magnetic Matters

Happy Holidays

As we close out what has been a particularly chaotic year for our industry and general trade, I want to express my appreciation for your involved effort. Through shifting supply chains, changing needs, and geopolitical challenges, working together and finding solutions side by side has made all the difference. This year proved once again the real power of strong partnerships. Thank you for your trust and collaboration, and I look forward to what we can accomplish together in 2026.

Tyee Harpster, President and CEO

Sometimes the magnet isn’t the problem—the design is

Allstar Helped an AI Robotic Company Solve a Magnet Challenge

When an AI robotic company came to Allstar Magnetics, they had a clear request: replicate a magnet they already had. But once our engineers reviewed the design, it became clear that the geometry they provided wasn’t manufacturable—and even if it were, it wouldn’t work the way they needed.

Instead of simply duplicating a flawed design, our team sat down with the customer to better understand the real requirements. Through this partnership, we uncovered both a sourcing issue and a manufacturing issue that were preventing them from getting the solution they needed.

By asking the right questions and leveraging our years of expertise, Allstar was able to:

Redesign the magnet for true manufacturability
Solve an additional performance problem the original design wouldn’t have addressed
Deliver samples quickly for fast testing and feedback
Provide pricing that was more favorable than their original path

The result was not just a working magnet—but a better solution that met deadlines, reduced costs, and performed reliably.

This project illustrates what makes Allstar different: we don’t just build what’s handed to us. We partner with customers, ensuring that what they’re asking for is truly what they need—and often deliver something even better.

If your design isn’t working or manufacturability is an issue, Allstar can help you find the right path forward. Let’s talk about how we can turn your challenge into a smarter solution.

ENGINEERS IN ACTION

by Shaunmarie Gutbezahl | Dec 15, 2025 | Allstar Magnetics News, Industry News

Redesigning for Success: How Allstar Helped an AI Robotic Company Solve a Magnet Challenge

When an AI robotic company came to Allstar Magnetics, they had a clear request: replicate a magnet they already had. But once our engineers reviewed the design, it became clear that the geometry they provided wasn’t manufacturable—and even if it were, it wouldn’t work the way they needed.

Instead of simply duplicating a flawed design, our team sat down with the customer to better understand the real requirements. Through this partnership, we uncovered both a sourcing issue and a manufacturing issue that were preventing them from getting the solution they needed.

By asking the right questions and leveraging our years of expertise, Allstar was able to:

Redesign the magnet for true manufacturability
Solve an additional performance problem the original design wouldn’t have addressed
Deliver samples quickly for fast testing and feedback
Provide pricing that was more favorable than their original path

The result was not just a working magnet—but a better solution that met deadlines, reduced costs, and performed reliably.

This project illustrates what makes Allstar different: we don’t just build what’s handed to us. We partner with customers, ensuring that what they’re asking for is truly what they need—and often deliver something even better.

If your design isn’t working or manufacturability is an issue, Allstar can help you find the right path forward. Let’s talk about how we can turn your challenge into a smarter solution.

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Engineers In Action

by Shaunmarie Gutbezahl | Nov 19, 2025 | Allstar Magnetics News, Industry News

What happens when a surgical device fails—and how engineering brings it back to life

A leading medical device company developed a surgical tool designed for use in operating rooms. During real-world procedures, however, the device revealed a critical issue: it would intermittently fail mid-surgery. While surgeons discovered a workaround to re-engage the tool and finish the operation, it was far from ideal.

Determined to resolve the problem, the device’s lead engineer went into the operating room to observe surgeons in action. By studying how and when the failure occurred—and why the workaround was effective—the root cause was identified: the power stage had been mis-designed and required a complete redesign.

What happens when a surgical device fails—and how engineering brings it back to life

From Prototype to Production: How Allstar Helped

The manufacturer turned to Allstar Magnetics, their magnetic solutions provider. Our team stepped in during the early development phase to help troubleshoot, prototype, and refine the redesign. Beyond solving the technical problem, we collaborated with the client to ensure the solution could be efficiently scaled into production.

By combining engineering expertise with practical manufacturing foresight, Allstar helped move the redesigned device from concept to reality—restoring reliability in the OR and protecting patient outcomes.

Advice from Our Engineers

Many of our medical device partners bring us in early in the design process, not just after problems arise, to fully benefit from our end-to-end engineering and manufacturing expertise. That’s because Allstar looks ahead—evaluating materials, manufacturability, and cost efficiency while prototypes are still being developed.

The payoff?

Time savings by identifying potential design and production challenges upfront.
Cost efficiency by aligning prototypes with scalable manufacturing processes.
Peace of mind knowing a collaborative partner is invested in both design success and long-term production quality.

As one client told us: “We come to Allstar for the expertise, but we stay for the partnership.”

Ready to troubleshoot an issue or launch your next device? Contact Allstar Magnetics today to discuss how we can support your project at every stage—from prototype to production.

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Smarter Solutions in Action: Custom Tooling for Adhesive Curing

by Shaunmarie Gutbezahl | Nov 6, 2025 | Newsletters

November 2025: Issue 4

Welcome to Magnetic Matters

At Allstar, strong relationships and creative problem-solving go hand in hand. This month, CEO Tyee Harpster reflects on the power of in-person partnerships, and our team showcases that same spirit with a custom adhesive curing solution built for smarter results.

At the Core: Notes from the CEO

The Real Infrastructure of Our Business

By Tyee Harpster, President and CEO

After five flights, ten hours of drives, six hotels, and forty-seven hours of meetings, I came home from Asia feeling tired—but mostly grateful. This trip through Singapore, Shanghai, Ningbo, and Bangkok was a whirlwind of collaboration, problem-solving, and connection.

From early-morning factory tours to late-evening dinners, every moment was a reminder that relationships are the real infrastructure of our business. Walking the production floor together with our partners, reviewing details, and planning for what’s next builds a kind of trust that simply can’t be replicated through email or video calls.

When we understand our partners’ capabilities firsthand, our customers benefit. We can anticipate challenges before they happen, find smarter sourcing strategies, and ensure reliability across every part of our supply chain. That’s what makes Allstar’s network so strong—and why face-to-face connection remains at the heart of how we do business.

And yes, even amid all the meetings, I managed to bring home one unexpected souvenir—a Labubu—proof that every trip brings its own surprises.

Thanks to everyone who welcomed me along the way and to the Allstar team who kept things running smoothly back home. Together, we’re proving that excellence comes not just from processes, but from people—and the relationships we build along the way.

Smarter Solutions in Action: Custom Tooling for Adhesive Curing

At Allstar Magnetics, we know that every project brings unique challenges. Recently, a customer came to us with a requirement: cure adhesive on specialized magnets and large assemblies at a specific temperature and amount of time. Normally, this would call for a massive industrial oven—an expensive and space-consuming solution.

Instead of passing that cost along, our team designed and built a custom oven in-house. By combining electrical and mechanical expertise, we created a flexible system that not only handled this project but can be adapted for future needs. We collaborated with the customer on the initial design of the unit, and now Allstar is refining it further—adding a control box to regulate and modify heat for even more precision.

The result? A solution that was faster, more cost-effective, and tailored to the customer’s needs. Just as important, this innovation adds long-term value: we now have a scalable capability to support similar projects going forward.

This project is a great example of how Allstar goes beyond being just a supplier—we’re a partner who listens, innovates, and finds better ways to solve problems.

Have a challenging project on your desk? Let’s start a conversation about how Allstar can help you achieve a smarter, more cost-effective solution.

Powering Research with Precision Magnet Solutions

by Shaunmarie Gutbezahl | Oct 2, 2025 | Newsletters

October 2025: Issue 3

Welcome to Magnetic Matters

In this edition we’re highlighting what really made the difference in a national laboratory’s next-generation accelerator project: supply chain management.

Read the full case study below and join the conversation on LinkedIn to see how smart supply chain management drives innovation across industries.

Powering Research with Precision Magnet Solutions

See how Allstar Magnetics helped a national lab keep its next-generation accelerator project on track by delivering highly specialized magnets exactly when and where they were needed.

Client
Our client is a U.S. Department of Energy national laboratory in New York, operating one of the nation’s most advanced particle accelerators. For over 20 years, they’ve trusted Allstar Magnetics as a strategic partner to supply high-energy magnetic components essential to their accelerator’s mission. Their work requires extremely precise engineering to channel and control energy beams in research aimed at unlocking new scientific discoveries.

Project Overview
Allstar Magnetics partnered with the lab as they developed critical components for a next-generation underground accelerator prototype—a project with the potential to reshape the future of accelerator research. The magnets required for the prototype were large, highly specialized, and needed to be integrated into custom steel assemblies—difficult to source, produce, and coordinate across multiple suppliers.

Timing was everything: the lab needed components delivered in sequence with their build schedule. Too early meant costly on-site storage. Too late meant research delays, stalled experiments, and wasted resources.

They needed a partner who could own the full supply chain—anticipating potential issues, consolidating multiple moving parts, and ensuring that the right products arrived at the right place, at exactly the right time.

Our Approach:
Allstar Magnetics served as a turnkey partner, overseeing sourcing, production, shipping, and delivery within one cohesive engagement. With a single call, the client entrusted the project to Allstar, confident that every detail would be managed.

Our coordinated approach included:

End-to-end sourcing and production – Engineering and manufacturing high-energy magnets and custom steel housings to exact specifications.
Precision logistics – Aligning shipping and delivery with the lab’s rebuild timeline so components arrived when needed—never too soon, never too late.
Supply chain simplification – Coordinating vendors, schedules, and assembly into one streamlined process.
One-stop accountability – Consolidating all work into a single invoice, eliminating administrative burden and freeing the client to focus on research.

In short, Allstar managed every step: sourcing, production, shipping, and delivery—executed as a single, seamless operation.

Results:
The accelerator’s beta efforts advanced seamlessly, enabling researchers to achieve higher beam precision, focus more energy on the system, and continue driving scientific discovery.

Because Allstar handled the complex sourcing, production, and delivery, the client’s engineers were able to stay focused on high-energy research rather than manufacturing and supply chain issues.

This partnership’s impact:

Maintained uninterrupted research schedules.
Delivered complex, high-spec components on time.
Strengthened a 20+ year partnership built on trust and execution.

Conclusion:
Allstar Magnetics is more than a supplier—we are a turnkey solutions partner. From sourcing and production to shipping and delivery, we take on complexity so clients can focus on their mission.

For high-energy physics, aerospace, industrial manufacturing—or any application where precision and timing are critical—Allstar delivers the confidence of knowing every detail will be right the first time.

Ready to power your next breakthrough?
Contact Allstar Magnetics to discover how our turnkey approach can simplify your supply chain and deliver the results your team needs to succeed.