1. Development of Lower-Cost BOM and Manufacturing: Allstar’s engineering team re-designed components to use equivalent but lower-cost materials, significantly reducing production costs without compromising performance.

1. First Article and Volume Production: Each SKU underwent a detailed first article process with client involvement to ensure compliance with specifications. Once approved, full-scale production was initiated.
2. Just-In-Time (JIT) Distribution: Finished goods were stored in a local warehouse and made available for delivery to the client’s foreign factory within four business days, providing the flexibility and efficiency the client required.
3. Just-In-Time (JIT) Distribution: The finished goods were distributed efficiently, leveraging Allstar’s robust supply chain and JIT model to meet the client’s manufacturing needs.

Results:
Allstar Magnetics delivered a solution that enabled the client to:

• Achieve significant cost savings with equivalent-performance components.
• Improve delivery times, ensuring JIT availability and enhanced operational flexibility.
• Reduce manufacturing risks and time to market.

Conclusion:  Allstar Magnetics demonstrated its unique ability to combine engineering, project management, and supply chain expertise to deliver a tailored solution for the client. By addressing cost, quality, and delivery challenges, Allstar helped the client achieve greater manufacturing flexibility, reduced risks, and improved overall efficiency, positioning them for sustained success in the competitive RV aftermarket power conversion industry.

Key aspects of the project included:

1. Consultative Design Support: The client provided basic specifications, and Allstar helped shape the technical design, material selection, and manufacturability to ensure that the components would meet electrical and regulatory requirements. Allstar proposed configurations, produced prototypes, and collaborated with the client through multiple iterations to finalize designs.
2. Patient Isolation Transformer: A crucial component was the patient isolation transformer, which provided necessary separation between the device’s power source and the patient to meet FDA safety standards. This transformer played a pivotal role in preventing electrical risks during surgery.
3. Prototyping and Testing: Allstar provided multiple rounds of prototypes for the client’s testing and proof of concept. Throughout the process, adjustments were made to ensure that the components performed optimally in the medical device’s RF generator.
4. Scalable Production: After successful testing and design finalization, Allstar scaled the production of the components, leveraging both in-house and offshore manufacturing capabilities. The design allowed for easy scalability to meet the growing demand for the medical device.

Results:

• Successful Product Launch: The RF generator launched successfully, and the device gained traction in the medical community, particularly in arthroscopic surgery for procedures like rotator cuff repair and tissue ablation. The components designed by Allstar have remained integral to the product’s long-standing success.
• Compliance with FDA Regulations: The power isolation transformers provided by Allstar ensured full compliance with FDA regulations, safeguarding patients from electrical risks during surgical procedures.
• Long-Term Partnership: The success of the RF generator contributed to a lasting relationship between Allstar and the client. Even as the original manufacturer was acquired multiple times, Allstar continued to supply the components for ongoing product iterations, making the collaboration a cornerstone of the device’s market longevity.

Conclusion: Allstar Magnetics’ expertise in custom wound components and collaborative design support allowed the medical device manufacturer to bring an innovative RF generator to market. The partnership enabled seamless scaling, compliance with stringent regulations, and continuous product improvement, contributing to the device’s success in the medical industry for over three decades.

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.

Key aspects of the project included: 

1. Collaboration with Semiconductor Partner: The power supply topology for the project required a specific microchip, designed by Fairchild Semiconductor (now part of ON Semiconductor). Allstar worked closely with the semiconductor company to design a custom transformer configuration tailored to this chip’s requirements. The collaboration resulted in a reference design, showcasing the power management solution that would later be adopted by other companies.
2. Customizing for Client’s Needs: Once the transformer design was published as part of the semiconductor company’s reference design, the client reached out to Allstar to customize the transformer for their specific application. Allstar adapted the reference design to meet the client’s unique power system requirements, ensuring optimal performance in their network and power systems.
3. Iterative Development Process: The project involved multiple iterations of the transformer design, with Allstar providing prototypes that were tested and refined based on the client’s feedback. Within 9 to 12 months, the team moved from initial prototypes to a finalized design, ensuring the transformer met all functional and performance criteria.
4. Scalable Production: Once the design was f inalized, Allstar scaled production to meet the client’s growing demand. The company leveraged its offshore manufacturing capabilities to produce hundreds of thousands of units annually, supporting the client’s large-scale deployment of their network systems.

Results:

• Seamless Integration with Power Systems: The custom transformer provided the high efficiency required for the client’s power systems, ensuring reliable operation for critical applications like fire signaling, surveillance, or security.
• Enhanced Collaboration: By working closely with both the semiconductor partner and the client, Allstar demonstrated its ability to collaborate across industries and design innovative solutions that integrate seamlessly into complex systems.
• Market Growth and Scalability: The project not only fulfilled the immediate needs of the client but also positioned Allstar Magnetics as a trusted partner for future growth. The client’s products gained traction, leading to large-scale production runs and ongoing demand for the custom transformers.