Problem:
SCALING COMPLEX PROTOTYPE TO A HIGH-VOLUME MANUFACTURING PROCESS
The prototype was a custom wire wound component. The design required a complex combination of milled ferrite, custom winding, and spot gluing of the wire. The design isolated components in a multi-piece set to allow for data and power to move independently without interference. The unique bench level design was not compatible with standard volume production methods. All attempts to use standard manufacturing methods had failed due to material, environmental and mechanical issues.
Solution:
CNC Programming & Winding for Product Mass Production
Custom CNC programming, cutting tools and optimized RPM levels were developed to manufacture the specialty milled ferrite. Fixturing using placement arrays allowed for high volume production across a 24/5 pre-programmed approach. Finished cores were wound and glued using a low touch process to dramatically reduced breakage while maintaining the specified inductance. All products were 100% tested and the data was sent directly to the customer. New packaging materials and layout were developed to assure consistent safe transfer directly to the customers’ production floor assembly.
Allstar Process:
Research & Material Development
Assessed Environmental Concerns and Complex Material Product Needs
CNC Milling
Optimized CNC Programming for Volume Cutting and RPM Levels
Prototype Conversion to Volume Production
Developed Mass CNC Programming Using Placement Arrays
Winding
Addressed Environmental Concerns While Protecting & Maintaining Product Inductance
Testing
100% Testing & Data Review With Client
Packaging
Customized for Optimized Floor Assembly
Benefit to Customer:
COMPLEX PROTOTYPE WAS TRANSLATED INTO A MASS-PRODUCED COMPONENT MEETING ENVIRONMENT & PERFORMANCE NEEDS
The wound milled ferrite set was the long lead item for the customer’s product. By developing and mastering a repeatable manufacture process the output for the finished good ramped 10x within 30 days. Most critically, the reliability and durability of the Allstar solution far exceeded expectations and led to the elimination the field failures associated with the milled and wound solution. Resulting contracts have been exponentially larger and allowed the entire program to progress from concept to growth phase.
Allstar Team Strengths
The combination of CNC milling and programming, winding, testing, and packaging expertise all revolving around unique material knowledge was what made the difference.
Prototype Analysis for Product Development Needs
CNC Programming & Winding for Mass Production
