A CASE STUDY: THE RIGHT COMPONENTS, AT THE RIGHT TIME, EVERY TIME

A CASE STUDY: THE RIGHT COMPONENTS, AT THE RIGHT TIME, EVERY TIME

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.

Powering Research with Precision Magnet Solutions

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.

Powering Research with Precision Magnet Solutions

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.

Engineers In Action

Engineers In Action

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.
 
Custom Tooling for Adhesive Curing
 
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.

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IRON CHROME COBALT (FECRCO) – A CASE STUDY

IRON CHROME COBALT (FECRCO) – A CASE STUDY

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

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

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)
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
Spacer
 
Part number: B67410-A0249-X187 N87 material
Leg
 
Part number: B62110-A6018-X087 N87 material
AUDIO MUSIC – A CASE STUDY

AUDIO MUSIC – A CASE STUDY

VINTAGE GUITAR PICKUPS

vintage guitar pickups

Recreating a Legendary Sound: How Allstar Magnetics Revived Vintage CuNiFe Pickups for a Global Guitar Icon

Client: World’s foremost manufacturer of guitars, basses, amplifiers, and related equipment.

Project Overview: In the music industry, the composition of magnetic pickups directly influences sound quality. A major audio manufacturer needed to re-create an obsolete magnetic material that had not been produced in over 60 years. The exact chemical composition was unknown, and customer demand for a vintage sound drove the need for a solution. Without a material formula or the ability to replicate the manufacturing process, the client turned to Allstar Magnetics for expertise in materials, manufacturing, and supply chain solutions.

Allstar’s Approach: Allstar Magnetics combined its deep material expertise and innovative manufacturing processes to address the client’s challenge. The approach involved recreating the custom magnetic blend, refining the manufacturing process, and ensuring scalability for volume production.

Results: Allstar Magnetics enabled the client to:

  • Recreate the original resonance and sound demanded by their customers.
  • Revive legacy products and develop new designs, driving organic sales growth.
  • Meet production demands efficiently through a reliable JIT distribution model.

Client Testimonial:
“For nearly 80 years, magnets have been an essential component of our products, contributing significantly to the unique sound that defines our brand and resonates throughout the music and audio industry. For over two decades, Allstar Magnetics has been an invaluable partner in this journey. Their expertise has been crucial in researching and manufacturing legacy alloys, developing innovative products, and maintaining a comprehensive stock of nearly 1,000 different magnet part numbers, all while supporting the evolving needs of the music and audio industry.”
– Chief Engineer, Guitar Research and Design

Vintage Pickups
Key aspects of the project included:

  1. Research & Material Testing: Allstar’s team conducted extensive research to recreate the custom magnetic composition, discovering additional materials beyond a standard blend that were crucial to achieving the original magnetic properties.
  2. Custom Magnetic Compound Development: The team developed a proprietary blending process and optimized the order of mixing raw materials to ensure exact performance characteristics.
  3. Prototype and Volume Production:: Allstar transitioned seamlessly from prototypes to scalable manufacturing, developing a process to achieve the final shape without altering magnetic performance.
  4. Just-In-Time (JIT) Distribution: The finished goods were supplied efficiently, leveraging Allstar’s robust supply chain and JIT model to meet the client’s manufacturing needs.
CuNiFe Pickups
Allstar Team Process:

  • Research & Material Testing: Custom magnetic composition and product research to ensure exact replication of vintage properties.
  • Prototype and Volume Production: Manufacturing expertise to transition from prototypes to high-volume production.
  • JIT Distribution: Efficient delivery of the final product to meet customer demand and support seamless integration into their production line.

Allstar Team Strengths:
Allstar’s team demonstrated unparalleled expertise in magnetic performance, manufacturing processes, and supply chain management. Decades of material knowledge allowed for precise reverse engineering and development of a custom magnetic blend. Their robust production capabilities and unique JIT distribution model ensured that the customer received the materials needed for a successful new product launch.

Conclusion:
Allstar Magnetics’ innovative approach and deep understanding of magnetic materials enabled the successful recreation of an obsolete product, helping the client restore their iconic sound. By partnering closely with the client, Allstar delivered a solution that met the demands of modern manufacturing while staying true to the legacy of vintage sound, driving significant growth and customer satisfaction.

THE POWER OF AS9100 CERTIFICATION – A CASE STUDY

THE POWER OF AS9100 CERTIFICATION – A 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.

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.