Custom Manufactured Gapped Toroid Filter Cores for Aerospace, Commercial & Military Use

Producing precision gapped toroid filter cores presents many manufacturing and engineering challenges. For toroid filter cores used in aerospace applications, tight inductance specifications are compounded by stringent quality requirements and the need for 100% conforming product. In this case study, we overcame these challenges to economically produce toroid filter cores that were able to meet all applicable aerospace standards and the requirements of aerospace customers across the globe.

We specialize in developing solutions for difficult problems; in this case, we engineered and built a custom manufacturing process designed for the production of gapped toroid filter cores. It is built around tightly controlled processes for air-gapping single and multiple-cut toroids. Our efforts resulted in products that exhibit reduced variance in inductance over powder cores and ferrites, with greatly improved shock, vibration and thermal characteristics.

This tighter control over inductance provides substantially improved noise filtering and thermal stability which is critical for applications such as fly-by-wire control systems used in aircraft. Our proprietary gapping and manufacturing process allows us to precisely tune the air gap within the narrowest inductance tolerances, which we verify using highly accurate Wayne-Kerr inductance analyzers. These unique resources and processes allow us to manufacture gapped toroid filter cores in single-, half-, quad-, and eight-cut gapped toroids, which can be supplied bare, epoxy coated, or with nylon or aluminum cases.

If you are interested in learning more about these products or the processes we use to manufacture them, contact us today.

Gapped Toroid Filter Cores Case Study Highlights

Project Name & Description Gapped Toroid Filter Cores

Capabilities Applied/Processes • Precisely controlled core bonding, cutting, gapping and testing

• Unique custom designed manufacturing equipment

• Highly accurate Wayne-Kerr Inductance Analyzers for testing

Overall Part Dimensions Highly variable custom sizes

Material Used All currently available soft magnetic tape materials

Material Finish Bare, epoxy coated, nylon or aluminum cased or custom cases

Industry for Use Aerospace, Commercial & Military

In Process Testing/Inspection Performed Inductance and other custom magnetic testing

Volume From prototypes to mass production

Delivery/Turnaround Time 3 weeks from Engineering to delivery

Delivery Location Worldwide

Standards Met DFARS, ITAR, ISO 9001-2008, AS9102 FAI available

Custom Processes for Manufacturing Long Bars Used in Magnetometers & Antennas

Within the magnetics industry, the manufacturing of long nanocrystalline bars has a reputation as a difficult item to produce economically. As highlighted in this product development project, MK Magnetics' biggest task was to overcome the fragile nature of long and narrow nanocrystalline bars while maintaining high permeability properties. Our initial goal involved producing bars with a .500" cross section and length of 24". With our technical insight into nanocrystalline materials and innovative process technologies, we established and then refined specialized manufacturing and assembly methods for producing bars with superior magnetic performance.

Once MK Magnetics stabilized the annealing and bonding process, we developed prototypes and subjected them to a rigorous set of tests to measure core loss, permeability, and inductance. Testing confirmed that we met all of the performance criteria, allowing us to ramp up to production-level manufacturing.

Since the initial development, we have expanded our production capabilities for these products to include even longer bars, up to 84"+ with cross sections as small .125". We also manufacture bars that require specialized machining and unique shapes. The flexibility of the manufacturing processes that we subsequently developed allows us to create geometries that are considered unconventional in the tape core industry. For more information, see the table below or contact us directly.

Long Nanocrystalline Bars Case Study Highlights

Project Name & Description Manufacturing Processes for Long Bars

Capabilities Applied/Processes • Unique assembly and manufacturing processes

• Special annealing and bonding processes

Overall Part Dimensions Typical Range: cross section from .125” x .125 to

2” x 2”+, lengths up to 84”+

Material Used Nanocrystalline for maximum permeability

Industry for Use Oil & Mineral Exploration, Directional Drilling

In Process Testing/Inspection Performed Core Loss, Permeability/Inductance

Volume Prototypes to mass production

Delivery/Turnaround Time 3 - 5 weeks typical

Custom Pulse Cores Used in Medical Imaging The Pulse Power Magnetic application has very specific magnetic core performance requirements. When engineers strive to build the best Pulse Power transformer, they need to consider core loss, saturation, wave form, and air gap, and, of course, cost. Very often engineers need to make trade-offs between system efficiency and magnetic performance. In an effort to maximize the best Pulse design, engineers should understand that MK Magnetics, Inc. has extensive knowledge of power loss, permeability, lamination breakdown and how they apply to pulse applications. MK Magnetics has developed annealing and bonding techniques to build the best performing cores for Pulse Power magnetics. Our technical expertise in annealing and overall process technology, along with sourcing the best and most cost-effective raw material worldwide has allowed us to build the most efficient and cost-effective Pulse Power cores.

In addition, MK Magnetics' years of experience, along with our deep penetration of the Pulse Power magnetic core market has allowed us to continually improve our processes, and reduce our costs, to build the best core available. On the back end, our concise quality control team along with state of the art test equipment and fixtures, insures that the customer gets what they want, on time, consistently.

MK Magnetics years of experience, and our very flexible processes, which include a variety of annealing ovens, annealing profiles, unique material coating equipment and methods, bonding technology, cutting machines and finishing processes, allows us to make the most custom part using the best combination of equipment for each specific core and customer requirement.

It is the understanding of magnetic properties desired and the knowledgeable selection of specific processes that is the foundation that results in the best core available to our customers. In addition, our technical staff is available to help engineers understand trade-offs and options available to develop the optimal core. We work closely with our customer in maximizing and perfecting the core design.

Custom Pulse Cores Case Study Highlights

Project Name & Description Pulse cores used in Medical Imaging

Capabilities Applied/Processes • Custom equipment and assembly methods

tailored to meet the needs of demanding high

voltage pulse transformers

• Custom tools and processes for stacked

assemblies

• Processes engineered specifically for pulse

transformers

Overall Part Dimensions From very small to very large pulse assemblies

Material Used Varies with pulse requirements. Wide variety of

materials and thicknesses for optimal results

Material Finish Special coatings available for high insulation

resistance and breakdown voltage

Industry for Use

Medical Imaging, Radar Systems, Particle

Accelerators, Military/Defense,

Telecommunications, Lithography, Lasers,

Klystrons, Satellite Communications, High Energy

Pulse Power Applications

In Process Testing/Inspection Performed Core Loss, Permeability/Inductance

Delivery Location Worldwide

Custom Magnetic Products for Renewable Energy Applications

The exponential growth in the renewables market has allowed Us at MK Magnetics, Inc. to become a major supplier of cores for transformers and low loss inverter and converter filter cores to this dynamic industry. Our products support solar and wind projects around the globe and include thermally stable, multiple -cut amorphous and nanocrystalline cores as well as large stacked and bonded assemblies. From small planar cores to cores weighing as much as 4,000 lbs. Our success in this market is built on a reputation for delivering standard and custom products that can meet the requirements of a broad range of applications. This is possible through advanced design capabilities and manufacturing processes that are at the forefront of the magnetics industry.

MK Magnetics' tape wound cores can be manufactured with multiple cuts and from various alloys such as silicon steel, amorphous, and ultra-low loss nanocrystalline. Manufacturing processes include computer-controlled annealing lines that take place in tightly controlled atmospheric conditions. We also utilize cutting edge insulative coatings and high strength, high-temperature proprietary bonding epoxies that provide superior quality bonds.

A key element in all of our manufacturing processes is quality; we operate an ISO 9001:2008 certified facility and conform to EIA standard RS 217 as a standard practice. Our comprehensive development to delivery solutions include volumes that range from a single prototype to long-term contract manufacturing. The value that we offer has allowed our products to be deployed in renewable applications that range from power generation to transportation.

To learn more about our full capabilities for renewable energy magnetics, see the table below or contact us directly.

Custom Magnetic Products Case Study Highlights

Project Name & Description Low Core Loss Inverter & Converter Filter Cores and Step

Up Transformers

Capabilities Applied/Processes • Custom computer-controlled annealing and

atmospheric conditions for optimal annealing of our

cores

• Superior bonding and cutting technology

Overall Part Dimensions Ability to manufacture from small planar cores to very

large cores in excess of 4000 lbs.

Tightest Tolerances ± EIA Standard RS217 typical or as required

Material Used

Any of our electrical steel material, from higher loss cost

effective Silicon Steels and amorphous to ultra-low loss

Nanocrystalline

Industry for Use

Photo Voltaic (PV) Solar Energy, Wind Power

Generation, Green Energy, Battery Chargers, Electric

Hybrid Vehicles: Automobiles, Buses, Mass Transit,

Motorcycles, Ships, Submarines, Locomotives

In Process Testing/Inspection Performed Core loss and other specialized magnetic testing as

required

Volume From prototypes to mass production

Delivery/Turnaround Time Typical 3 - 4 weeks with expedited delivery available

Delivery Location Worldwide

Standards Met ISO 9001:2008

Advanced Nanocrystalline Cores for High Frequency Applications

Nanocrystalline cores are used in more new applications than any other core material. The use of nanocrystalline cores for high-frequency applications have historically been associated with high material costs and narrow core widths. This has led many designers to sacrifice performance to appease budgetary concerns. However, this has changed due to the release of a new domestically produced nanocrystalline material called Finemet® FT-3W. This newly developed source of material has allowed us to offer DFARS compliant, large stacked, and even larger unstacked cores up to 5.6".

The positive feedback MK Magnetics, Inc. received from our customers was immediate. Our combination of new materials and manufacturing processes exceeded all expectations for performance and allowed customers to penetrate and compete in markets that had previously been unavailable due to core costs.

As with all of our products, our nanocrystalline cores are a custom product, and available to meet specific design requirements. Our manufacturing processes utilize a specialized annealing system that is controlled based on design frequency. Cores' profiles can be configured in C, E, Toroid, bars, and more as well as sizes such as standard AMCC, as single, unstacked, or custom sizes. They can also be manufactured with multiple cuts to reduce fringing losses if needed or configured for machining to fit custom applications. As a customer centric manufacturer, we offer a high degree of engineering support and are geared for flexible manufacturing volumes, from a single prototype or proof of concept, up to large scale mass production. For more information on MK Magnetics, Inc. nanocrystalline cores, contact us directly.

Advanced Nanocrystalline Cores Case Study Highlights

Project Name & Description

Developed processes to utilize newly available

domestically supplied lower cost, wide width

Nanocrystalline (Finemet® FT-3W). Other

nanocrystalline materials available: Finemet® FT3

(Finemet® FT3 is a registered trademark of Hitachi

Metals), Vitroperm800® (Vitroperm800® is a registered

trademark of Vacuumschmelze).

Capabilities Applied/Processes • Custom computer-controlled annealing and

atmospheric conditions for optimal annealing of our

cores

• Superior bonding and cutting technology. Large

sized processing equipment

Overall Part Dimensions Large core sizes available up to approx. 84”

Material Used

Nanocrystalline (Finemet® FT-3W)

Metglas Finemet® FT3-W is a registered trademark of

Metglas Inc

Industry for Use Widest scope of industries for any material

In Process Testing/Inspection Performed Core loss and other magnetic testing as required

Volume From prototypes to mass production

Delivery/Turnaround Time Typical 3-5 weeks delivery with expedites available

Delivery Location Worldwide

Energy Harvester Cores for Smart Grid monitoring Applications

Smart grid applications encompass many technologies and represent a leading growth area within the Power Utilities and renewable energy industry. At MK Magnetics, Inc., we support smart grid deployments with components such as energy harvesting cores. These are inductively powered coupling devices that enable the collection and transfer of energy under low line current conditions. Our specialization in tape wound cores allow us to offer the most energy efficient and cost effective solution for induction-based energy harvesting. These products are engineered to meet the magnetic, power density, and environmental demands specific to energy harvester cores. As a result, our expertise in engineering and manufacturing cores gives us the ability to maximize designs and utilize the optimal combination of features, materials, and manufacturing processes. For example, in applications where cost is a major concern, we can build cores from silicon steel. For high-performance designs, we can manufacture cores from high nickel and nanocrystalline materials.

One of the advantages of working with MK Magnetics is our customer-centric culture; our goal is to build long-term relationships by delivering the maximum value and performance with every project engagement. The quality and performance inherent in our products are highlighted in the fact that our energy harvester cores have been deployed in smart grid applications across the globe.

What we offer our customers is unique in the industry, responsive customer service, unmatched performance, and lead times of just three weeks. For more information, or to learn more about the advantages of working with an industry leader, contact us directly.

Energy Harvester Cores Case Study Highlights

Project Name & Description

Determine best possible materials and processes for the

most effective use of power harvesting available for

Smart Grid monitoring.

Capabilities Applied/Processes Superior bonding and annealing technology that

produces optimum results

Material Used Silicon steel for lowest cost, high nickels and

nanocrystalline for best performance

Industry for Use Smart Grid, Local Power Distribution, Power

Transmission

In Process Testing/Inspection Performed Specialized testing to meet the needs of this unique type

of product

Volume From prototypes to mass production

Delivery/Turnaround Time 3 weeks from Engineering to delivery

Delivery Location Worldwide

Low Loss Solution to Energy Storage Inverters Tape wound soft magnetic cores are a mainstay in the energy storage industry, where the use of highly efficient, low-loss inverter filter cores are critical. In support of the cost savings efforts of one of MK Magnetics' customers in this industry, we introduced them to our Optifficient brand of ultra-low loss amorphous cores. Composed of cutting-edge materials such as Metglas® 2605SA1 magnetic alloy, these custom products are manufactured with optimized annealing and bonding processes, and delivers up to 30%+ lower loss than standard amorphous cores being sold by other suppliers, depending

on frequency and flux density. We specialize in developing solutions for difficult problems; in this case, we engineered and built a custom manufacturing process designed for the production of gapped toroid filter cores. It is built around tightly controlled processes for air-gapping single and multiple-cut toroids. Our efforts resulted in products that exhibit reduced variance in inductance over powder cores and ferrites, with greatly improved shock, vibration and thermal characteristics.

In this project, we worked in close collaboration with the client’s engineering team to develop a low loss solution that would seamlessly integrate into their line of energy storage devices. The challenge was to develop a product that could meet the core loss requirements and be manufactured within tight budgetary constraints and to an aggressive timeline. Additionally, this project would require cut C-cores of varying dimensions weighing up to 25 lbs., but not limited to this size.

As a complete solution, this example represents design development, prototyping, and mass production. Because of our specialization in core manufacturing we have assembled a range of custom and standard equipment that is supported by a highly experienced staff and a comprehensive quality program. This combination of resources and capabilities resulted in a customer whose expectations were far exceeded. It has also led to a long-term relationship that continues today.

To learn more about this project, or the processes used to complete it, contact us directly.

Ultra-Low Loss Amorphous Cores Case Study Highlights

Project Name & Description Low Loss Solution

Capabilities Applied/Processes • Special anneal & bonding processes

• Special annealing furnaces and control systems

Overall Part Dimensions Various multiple cut C-cores sizes up to 25 lbs.,

but not limited to this size

Material Used

Amorphous Metglas 2605SA1® Amorphous Metglas 2605SA1® is a registered trademark of Metglas Inc.

Material Finish Bare, epoxy coated, nylon or aluminum cased or custom cases

Industry for Use Energy Storage

In Process Testing/Inspection Performed In process and finished core loss measurements

Volume Prototypes to mass production

Delivery/Turnaround Time 3 weeks from Engineering to delivery

Standards Met Met and exceeded customer requirements