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.

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.

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.

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.