Why Engineers Choose Allstar: Designing with Scale in Mind

That’s where Allstar comes in.

Designing with Scale in Mind

When companies pull us into the process early—at the prototype stage—we can help ensure that the design choices being made won’t become roadblocks later. We bring both technical application expertise and real-world manufacturing knowledge to the table. That combination is what sets us apart.

Instead of only thinking about function, we also ask:

• How easy will this be to manufacture at scale?
• Will the chosen materials hold up in production without blowing up the budget?
• Can we simplify the design to improve reliability and reduce cost?

These are questions every engineer needs to consider before moving past the prototype phase.

Partnering Early Pays Off

By working with Allstar at the beginning, your prototype isn’t just proof of concept—it’s a foundation for production. That means when you’re ready to move from small runs to full-scale manufacturing, your design is already optimized to be built efficiently, cost-effectively, and at volume.

Customers choose Allstar for our technical and manufacturing expertise—and stay because we operate like an extension of their development team, anticipating what it takes to turn innovation into reality, seamlessly and without surprises.

If you’re an engineer working on your next big design, don’t wait until the production phase to think about manufacturability. Bring in a partner who can help you scale smart from day one.

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

• 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.

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.

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.

Smarter Solutions in Action: Custom Tooling for Adhesive Curing

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