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Mag Manufacturing: Driving Efficiency in Transformers

Transformers have long been a crucial component of any electrical system, helping to safely and efficiently step up or down voltage through the system. However, like any functional part, transformers are never 100% efficient when it comes to real-world applications–but they can get very close. 

When it comes to custom mag manufacturing, getting the utmost efficiency out of a transformer is often a must, especially in industries that require high performance out of their electronics. And there are a few general ways that transformers can be improved through good manufacturing and careful planning. 

Precision Coil Winding

Transformers consist of a solid core surrounded by two coils of wire, and everything about how these wires are wound about the core contributes to the transformer’s performance. The space between each individual turn around the core, the material, diameter, and length of the wires themselves, how the wires are actually wound about the core, and related factors all have a role to play in the performance and efficiency of a transformer. Coil winding has significantly improved over the past decades as well, with automation and CNC equipment allowing for a variety of styles and dimensions of coils

Proper Insulation and Encapsulation

Transformers tend to generate a lot of heat, which can impact their efficiency and even potentially damage individual components. Properly insulating the coils and the transformer as a whole helps with protecting the final product from this heat. Various types of encapsulation will also help insulate the transformer from its environment, especially in demanding applications like military and aerospace electrical systems. For instance, SI Manufacturing offers options for vacuum or pressure multi-compound encapsulation on request. 

Looking for a supplier of custom mag manufacturing services?

SI Manufacturing offers full custom electronics solutions, providing each of our clients from design to delivery with over four decades of experience in custom magnetics, precision winding, and custom power supply manufacturing. If you’re interested in learning more about what we can do for you in mag manufacturing, contact a member of our team today.

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Understanding Mil-Spec Magnetics for Defense Applications

One of the major capabilities that we have here at SI Manufacturing is providing full solutions for clients needing MIL-SPEC magnetic components, for use in defense, aerospace, and related systems. And today, we’re exploring exactly what MIL-SPEC means and how manufactured components like magnetics and other electronics made to these specifications differ from the norm.

MIL SPEC and STD: The Difference in Scope

The Defense manufacturing industry has some of the strictest standards to ensure reliability, performance, and quality of anything made for use in defense-related equipment and applications. Any contractor who works in the industry will run into two terms–MIL-SPEC and MIL-STD. And while they may seem similar, these two regulations cover different aspects of the actual products and services that the Department of Defense (DoD) purchases. 

MIL-STD, or military standards, document technical requirements for military-specific or modified commercial processes, procedures, practices, and methods. These can include technical documentation and cybersecurity, design criteria, manufacturing processes, and testing methods.

MIL-SPEC, or military specifications, is a specific documentation of the technical requirements for an individual purchased material used in military applications, and is often used in connection with the actual technical data sheet (TDS). MIL-SPEC documents lay out the requirements for that material’s performance as an individual component, its performance in the larger system, and any other details such as how to fulfil certain requirements, assemble and integrate a product, or even fabricate and design the product. 

MIL-SPEC Magnetics Components vs. Commercial Magnetics Components

What sets magnetics labeled and manufactured as MIL-SPEC compared to other custom-manufactured magnetics is mainly the standards that the product has to meet. Every aspect from design to manufacturing to testing is carefully monitored and planned out for MIL-SPEC magnetics. A higher performance standard is also expected of these types of custom magnetics components, especially when it comes to component reliability under severe, real-world conditions and long-term use. While the actual characteristics and standards will differ across individual components, overall the MIL-SPEC label indicates that the magnetic component will perform better, last longer, and overall be made to a higher quality standard than everyday magnetic components–which is crucial in an industry where the end-use product’s functionality can be the difference between life or death.

MIL-SPEC Magnetics at SI Manufacturing

SI Manufacturing provides custom magnetics for some of the world’s most demanding and rigorous applications, and one of the most stringent of those markets is Defense equipment manufacturing. SI has long been a trusted partner for MIL-SPEC magnetics solutions used in a variety of Defense-related applications, known for its ability to quickly adapt to client needs and provide rapid turnaround on RFQs and finished products. Contact us for more information and to request a quote.

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Selecting Reliable Custom Transformer Manufacturers

Transformers are the backbone of electronics, and performance and quality are a must when it comes to these small but crucial components. So when you’re looking for a custom transformer manufacturer, you need to make sure that you find a manufacturer that can handle the quality, customization, and performance of your particular transformer design. Here are a few things to consider when you’re selecting an electronics manufacturer for your transformers. 

Do they adhere to the standards of quality necessary for you and your industry?

Certain industries, such as Defense and Aerospace, have stricter regulations when it comes to the design, performance, and quality of custom transformers. And reliable performance is necessary for any transformer, so it’s important to find a manufacturer that not only is familiar with your particular industry, but also has a reputation for excellence when it comes to quality. See what their past customers have to say about them, through reviews on their website or customer testimonials. Be sure to ask them about their quality management system and any certifications that they hold that would be relevant to your particular market or needs.

Do they offer the capabilities and capacity that your project requires?

Every manufacturer is different, whether that be through the particular industries they specialize in, the production capacities they prefer, and the services and customization options they offer. For instance, some companies are better equipped to handle prototypes, one-offs, and small production, while others handle large scale projects with high volumes. Then you have to consider the actual types of transformers that they can make, including features such as size, voltage, encapsulation, and more. Some companies, like SI Manufacturing, also offer additional manufacturing capabilities, like full assemblies and custom power supplies, bringing everything you need in-house rather than forcing you to outsource certain parts of the product to different companies. 

How much experience does the manufacturer have?

The length of time that a company has been in business can say a lot about their dedication to their customers, and as well as their responsibility when it comes to finances, project management, and customer service. Companies like SI Manufacturing that have been in business for decades will not only be much more experienced in transformer and magnetics manufacturing, they’ll also be much more stable and reliable, both now and for years to come. 

Looking for a custom transformer manufacturer that you can rely on?

SI Manufacturing has been a manufacturer of custom electronics since 1952, having grown up alongside the industry to become a trusted partner for some of the most demanding industries in the world, such as Defense, Aerospace, and Industrial Equipment. Head over to our website to learn more about what we have to offer and request a quote today.

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SI Manufacturing is Proud to be CMMC Compliant

SI Manufacturing is one of a few custom electronics manufacturers that serves the demanding requirements of Defense applications. We are ITAR registered and AS9100 certified, and regularly manufacture MIL-spec electronics solutions. While the CMMC certification was in the works, we were closely following the requirements that would be needed so that we could quickly get our certification when the time came. 

What is CMMC?

The Cybersecurity Maturity Model Certification (CMMC) is a framework created by the Department of Defense (DoD) to ensure that any contractors and companies who handle sensitive government information. In other words any contractor for the DoD who handles information like Controlled Unclassified Information (CUI) and Federal Contract Information (FCI), will soon be required to adhere to strict cybersecurity standards. 

Before the creation of CMMC, defense contractors just assessed themselves internally to ensure that they were compliant with DoD security standards. Starting in early 2025 though, nearly all contractors for the DoD will have to be assessed by an independent third party who is trained specifically under CMMC requirements. 

CMMC Compliance at SI Manufacturing

Recently, the CMMC Final Rule (CFR 32) was officially published, meaning that certification would be required in the coming months. SI Manufacturing is one of the manufacturers who has been closely following the updates for CMMC so that we could be compliant with its standards ahead of time. This will allow us to get audited and certified quickly as requirements for CMMC are put into place in 2025. We’ve been working with the industry for a long time, providing full solutions for specialized defense electronics used in all different types of critical applications, so we know the importance of maintaining high standards in both security and performance. 

Are you looking for an electronics contract manufacturer for Defense applications?

SI Manufacturing offers full manufacturing solutions for precision magnetics, PCB assemblies, custom power supplies and more for the stringent requirements of Defense equipment manufacturing. Contact us today to learn more about what we can do for you!

transformer coils

A Brief Look into Custom Transformer Design Considerations

Custom magnetics have always been SI Manufacturing’s specialty. Precision windings for transformers are the heart of what we do, and have been since our humble beginnings in the 1950s. Today, we  manufacture custom transformers for some of the world’s most demanding applications, helping our customers push the boundaries of what’s possible in electronics. 

Transformers have always played a crucial role in any type of electronic device, no matter how big, small, simple, or complex. They are necessary for controlling voltage levels between different circuits, ensuring efficient power distribution and voltage regulation within the device, greatly impacting the performance of the end-use product. And because they have such a huge impact on the performance of the final electronic assembly, a lot goes into the design of a custom transformer, especially for high-reliability and high performance applications. 

Design Considerations for Custom Transformers

When we help our customer design custom transformers and windings, we have to keep a lot of things in mind, like the application requirements for performance, the load characteristics expected of the final result, the environmental conditions the final assembly will encounter, and the industry regulations that the transformer needs to meet. We also have to plan for testing the finished transformer to ensure that it meets the specific performance criteria set out for it, such as voltage, power ratings, physical size, and thermal management. 

Transformer Cores

The first thing we do when we collaborate with a customer on a custom transformer design is determine the best core material and the best configuration of the core. This decision will massively impact the transformer’s efficiency further down the line, as each material has its own unique properties that affect the transformer’s magnetic properties and core loss. As electronics become more and more miniaturized, especially in industries like Aerospace where weight and size constraints are increasingly more regulated, we also have to balance the size constraints of the core material with its performance. Certain materials may not meet the performance requirements of the initial design within the size constraints. 

Transformer Windings

Once we’ve determined the core material, we then have to plan the winding around it. Transformer windings are the other crucial half of the custom transformer, as they ultimately have the most impact on its functionality. We have to consider the type of wire and determine the right wire gauge and insulation material to prevent overheating and short circuiting, and then perform the actual winding, which is an incredibly delicate task that requires significantly high precision to get the right amount of loops around the core. Proper and precise winding will reduce leakage flux and improve energy transfer, but even small mistakes can have a big impact on the transformer’s performance. 

Final Thoughts

The final application of the transformer will often have the biggest impact on its design. Transformers are typically customized for very specific uses, which involves making difficult decisions of the winding configurations and materials, as well as determining the right core so that the final product meets industry requirements. It’s always important to keep in mind the end-use requirements of the transformer and the various conditions it will encounter when designing a custom one. 

Are you looking for a custom electronics manufacturer specializing in the most demanding applications across Aerospace, Defense, and Industrial equipment? Contact us to learn more about what we can do for you!

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Quality First: Best Practices in PCBA Contract Manufacturing

PCBA contract manufacturing is a widespread and crucial service in the electronics industry. Nearly every type of electronic device depends on PCBs directly or indirectly–so ensuring quality throughout the production of PCBAs is a must. In this article, we’re taking a look at a few of the best practices for PCBA contract manufacturing, whether you’re looking to secure PCB manufacturing and assembly services, or you’re a supplier of those services like us here at SI Manufacturing!

Designing your PCBs to become a Reality

All manufacturing projects start with a design–and PCBAs are no different. If the design doesn’t take into consideration the actual manufacturing of the board, then problems are much more likely to occur later on in production. It’s important to perform a design rule check (DCR) to make sure that the design meets the constraints of the actual technology that will be used to make it. This includes not only size and dimensions, but also component alignment and spacing, PCB functionality and reliability, and overall possible production volume. Or in other words–can the design be produced using current equipment and at the necessary volumes, and when it’s finished, will it meet the functional requirements that it was initially designed for?

The DCR is a lot like a design for manufacturability (DFM) inspection, but aimed more at PCB manufacturing. The goal is to identify any design errors early on in order to avoid dealing with these issues later on in production, when they’ll be much more costly to correct.

Collaboration and Communication

Good contract manufacturers understand the importance of collaboration and good communication. You should have a clear line of communication with your manufacturing partner, and in turn they should take the time to fully understand the requirements for the form, fit, and functionality of the final PCB. Good communication can also make any necessary changes to the design a lot more efficient.

Another advantage of a good, collaborative electronic contract manufacturer is their experience. They’ll often be able to offer advice based on their own expertise on ways that the design or production process can be adjusted for improved lead times and cost efficiency, or even more reliable functionality. 

Quality Control and Industry Certifications

Quality control and inspection methods are always crucial for ensuring the PCBA meets the functionality required of it. This can involve any number of inspections at any point in the process–from incoming material inspections to ensure everything matches the BOM to sample testing PCBs at different stages to ensure they’re meeting requirements. For example, SI Manufacturing will perform not only functional testing, but also environmental testing on request to ensure that the PCBs will perform well in certain environmental conditions. 

Another important part of PCBA contract manufacturing, depending on the industry, is quality management system certifications, like ISO 9001 or AS9100. These certifications imply that the certified manufacturer has a quality management system in place that meets globally-accepted standards for quality control and inspection throughout their facility. They’re also occasionally required by certain industries, especially for system-critical PCBs that will have an impact on the health or safety of a person, or if the end-use device will encounter particularly harsh environmental conditions. 

About SI Manufacturing

SI Manufacturing is an expert supplier of PCBA contract manufacturing services, maintaining ISO 9001 and AS9100 certifications for quality management and serving some of the most rigorous applications in Aerospace, Defense, and Industrial Electronics. Contact us today to learn more about how we can help you!

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Future Trends: What’s Next for Precision Manufacturing in Anaheim?

Southern California has long been the hub for the high-tech industries, and just like everywhere else in the world, electronics precision manufacturing in Anaheim is being shaped by advances in automation, IoT, and smart technologies. Anaheim precision manufacturing for electronics and other tech industries will continue to evolve and grow, improving in efficiency as new methods are adopted and process monitoring improves. Here are a few of the trends shaping the future of Anaheim precision manufacturing for electronics. 

Increased Demand for Customization

As technology continues to advance, many OEMs are looking for custom or built-for-purpose PCBs and electromechanical assemblies for their products. They’re looking for customized solutions, precision manufacturers who can work with them to help bring their visions to life. As technology continues to advance, the need for custom precision manufacturing will likely increase, as will the need for equipment to handle that custom work.

Continued Push for Sustainability

Sustainability has become a significant driving force for every sector of manufacturing, and electronics is no exception. This involves not just sustainably-sourced materials–though this has become a significant selling point for many manufacturers–but also finding ways to reduce energy consumption and material waste during the manufacturing process. 

Smarter Technologies–IoT and AI

More and more, across industrial, residential, and commercial applications, there is an increased demand for smart technologies and devices. IoT integration offers the user or facility a way to interconnect a wide range of equipment, devices, and softwares in order to collect, store, share, and provide easy access to important data. The use of AI in manufacturing equipment has improved both the precision, repeatability, and process monitoring capabilities across many industries.

Miniaturization

Miniaturization isn’t just about handheld devices–though they have grown exponentially in popularity in recent decades. Many OEMs are seeking smaller, more compact electronics to save on space and weight, especially in automotive and aerospace applications, to improve the efficiency of vehicles, aircraft, and spacecraft. 

Final Thoughts

The future of Anaheim precision manufacturing is set to be shaped by improvements in automation, smart technologies, and a push for sustainability and increased customization. With further integration of AI and IoT, electronics manufacturers will be able to enhance their efficiency and precision, and set new benchmarks for quality and productivity. 

About SI Manufacturing

SI Manufacturing is a custom electronics manufacturing company that has grown up alongside the industry. Founded in 1952, we were built on a dedication to challenge ourselves, tackling the problems that others wouldn’t. If you’re looking for an electronics manufacturer, consider partnering with us and request a quote today!

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Meeting Critical Defense Equipment Requirements with Quality Magnetic Components Manufacturing

SI Manufacturing is a trusted partner for electronics and magnetic components for some of the most stringent industries in the world. One of our major specialties is in Defense and Military equipment manufacturing. 

Meeting Strict Quality Requirements through Certifications

Defense equipment manufacturers have incredibly strict requirements when it comes to the quality and performance of their electronics systems. SI Manufacturing maintains several certifications so that we can be sure that we’re meeting the high standards of our partners in this industry and providing them with magnetics that they can rely on. We are both ISO 9001:2015 and AS9100 certified for electronics manufacturing, as well as ITAR registered to ensure the safe transfer of technical documentation between our facility and our customers.

As a PCB manufacturer, we also have to meet the highest standards for soldering and soldering inspection. We can meet PCB assembly and soldering standards as laid out by the IPC J-STD-001 Class 3 regulations, which are often necessary for critical Defense systems. 

Meeting Strict Performance Requirements through Electronics Expertise

Precision magnetics are essential for just about every type of electronic device imaginable, and SI Manufacturing has made virtually all of them in our time. We can produce a variety of custom transformers able to manage up to 50kV, as well as inductors and reactors that have to withstand high levels of vibration or other extreme conditions. Our precision windings can be found in systems that require the precise control of movement or exceptionally reliable performance. 

We also have thorough quality inspection and testing capabilities for all PCB and magnetic components in-house, including electrical, functional, visual, mechanical, and environmental testing. Nearly all of the components that we make end up in a system that has to endure some sort of harsh conditions, so not only do we work with our customers to make the custom components that they need, we also fully test them for proper functionality. 

We are a custom electronics manufacturer that has grown with the electronics industry, adapting to its ever-changing demands and landscape, whether that be through maintaining new quality standards, introducing new production technologies to our shop, or helping our customers bring new designs to life. 

Looking for a custom electronics manufacturer in the Defense industry?

SI Manufacturing is your partner in technology and custom electronics and magnetics manufacturing for a wide range of specialty applications, including Defense equipment. Head over to our website to learn more about what we can do for you and request a quote today!

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Quality Assurance in Aerospace Assembly

Anything that is made for the Aerospace industry, especially when it comes to flight critical electronics or structural parts, has to go through a rigorous quality assurance process to ensure the safety and reliability of the final product–the aircraft. The actual assembly of various aerospace components into a full system includes some sort of comprehensive testing and inspection at each step of the process.

In order to maintain high quality aerospace assembly components, manufacturers like SI Manufacturing adhere to stringent certification standards that are recognized internationally as the best assurance for safety, reliability, and performance of any aircraft. 

Soldering to Perfection–IPC J-STD-001 

The IPC J-STD-001 is the gold standard for soldering work on just about every type of PCB. This type of quality certification outlines the materials, methods, and verification criteria required for manufacturers of electronic assemblies, and covers three different subsections of PCB soldering requirements, designated as Classes. 

Class 3 is the strictest of the IPC classes, and specifically covers soldered electronic assemblies in applications that cannot fail–which are often Aerospace applications, though the standard is used for many other types of assemblies as well. Products belonging to Class 3 are required to provide continually high performance on-demand and are often used in uncommonly harsh environments, and they are also typically either mission critical or flight critical.

The J-STD-001 certification offers guidance for many different parts of electronic assemblies beyond soldering as well: what materials and components to use, the type of equipment used for manufacturing and assembling the products, specifications for surface and through-hole mounting, terminal and wire connection standards, the coatings, encapsulation and adhesives that can be used, and requirements for any cleaning done. It offers a very comprehensive guide that ensures that all soldered interconnections are high quality, and the final assembly adheres to worldwide industry standards.

Rigorous Quality Management–AS9100D

Another critical aspect of ensuring excellence in aerospace equipment and electronic systems is the manufacturer’s quality management system, which lays out all inspections and testing procedures that should be performed. The AS9100D certification is heavily based on the more well-known ISO 9001 standards, but has been adjusted and expanded to include several additional requirements for aviation, space, and defense manufacturing. It lays out the requirements for a quality management system at all levels of the supply chain to ensure consistent quality and compliance with industry standards in all aerospace assembly components.

Looking for an Aerospace electronics contract manufacturer?

SI Manufacturing is an AS9100 and IPC J-STD-001 certified manufacturer of electronics assemblies for Aerospace, Defense, and Industrial applications. If you’re interested in partnering with us, head over to our website to request a quote today!

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Powering Modern Electronics: The Role of Magnetic Components

Magnetic components are a crucial part of keeping nearly every type of modern electronic device functional. They can be found just about everywhere, providing essential functions such as filtering, energy storage, and power conversion, and play a major role in driving the development of more efficient and more compact electronic systems. Without magnetics, much of the technology that we have today wouldn’t be possible. 

A Quick Guide to Magnetic Component Basics

Magnetics are materials that exhibit attraction and repulsion to other materials, and generate a magnetic field, much like a small force field. This field can change the direction of an electric current, converting magnetic energy into electrical energy and back again depending on how the magnetic field is manipulated. The strength and direction of the magnetic field can be adjusted to meet specific requirements for different applications.

Using Magnetics for Power Conversion

One of the major benefits of magnetic components is their ability to convert different types of energy. They can be found in conjunction with coils in electric motors. When the coils are energized, they create a magnetic field that interacts with that of the actual magnetic component. The magnet then generates a rotational torque that causes the motor’s rotor to spin, essentially turning electric energy into mechanical force. Magnetic components are essential for transformers as well, which convert electrical energy into very specific voltages. These are crucial components for ensuring the safety of an electrical device and protecting it from damage. 

Managing Electric Currents

Magnets are used to create electric currents all the time, whether that’s through wrapping a magnet around a wire, or winding a wire around a magnet. These highly precise windings can then be used to carefully manage the direction and strength of the current, as well as direct them towards the rest of the system. 

Magnetic Storage Cores

Magnetic cores are a common find in all different types of energy storage applications, as they can be configured in a variety of ways. These types of magnetic components can be used to harvest and convert energy, like in conductors and inductors. They’re also important for transferring energy across different pieces of equipment, and storing energy within a device as well, ready to be converted at any time. 

Looking for a manufacturer of magnetic components and precision windings for magnetics?

SI Manufacturing is your partner for technology, and we serve the most demanding industries with our electronic contract manufacturing services. Request a quote today!

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