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A Device For High Voltage Testing, Voltage Regulation In Dielectric.

HIPOT Testing

HIPOT Testing

SI Manufacturing recently walked our customers through the advantages of using encapsulations for their projects. In addition to the information presented in that previous blog post, we use encapsulations because they deliver a thicker layer of protection to our products, giving them a more remarkable ability to function correctly for longer lengths of time. This encapsulation process improves the results of HIPOT testing. 

HIPOT testing is a vital step in manufacturing custom magnetics. SI Manufacturing is proud to provide a wide range of testing capabilities that work alongside our encapsulation options.

What is HIPOT Testing?

HIPOT testing is also known as High Potential Testing. This test utilizes high voltages to determine whether the magnetic component can be relied upon to perform under large amounts of stress. Rather than exposing the assemblies to the amount of voltage used during typical usage, HIPOT testing uses considerably stronger voltage levels to ensure that integral components will not fail, even when subjected to extreme conditions.

As a company that serves industries that require the utmost reliability from their components, such as the aerospace and defense industries, SI Manufacturing takes our HIPOT testing strategies incredibly seriously. Using thorough HIPOT testing equipment, our team can detect any gaps or points of degradation that may threaten our products’ functionality.

How Hipot Tests Work

As mentioned above, HIPOT testing verifies the quality of many electronic and electromagnetic products using high-voltage power. The test works by connecting the supplied power both to the ground and to the tested product. Because various magnetic components will each present their own unique challenges and voltage requirements, there is no standard HIPOT test. Instead, specific testing levels can be determined using product type. And because Hipot testing typically involves hazardous voltages, the testing team must thoroughly understand the entire testing process. Our team is highly experienced in what we do, which is why we can provide the precise HIPOT test capabilities required for every project that we take on.

Rotor,And,Stator,Detail,Of,Electric,Dc,Motor,Isolated,On

Experience with Many Types of Encapsulations

SI manufacturing makes it our mission to possess expertise in all areas of custom electronics manufacturing service. One area, in particular, which our company has invested significant time and resources to develop is encapsulation. Electromagnetic coils and components are crucial to the functionality of the systems they are designed for, and as such, it is in a manufacturer’s best interest to protect these components using the best techniques available in the industry. 

Encapsulations are the ideal first-defense for coils, acting as a shield against harsh environments, high moisture levels and harmful fluids, and even improve electrical performance, especially at higher voltages. Beyond protecting coils from the general facility conditions that these parts will be used within, encapsulations can also be used to protect coils from damage during the handling and assembly processes. By maximizing the amount of safeguarding during every stage of custom electronics manufacturing, SI Manufacturing is able to provide customers with products that will last as long as they are needed.

Types of Coil Encapsulations: Vacuum Encapsulations

Vacuum encapsulations, also known as vacuum potting, is becoming an increasingly popular method of coil protection. By using an air-free technique during the encapsulation process, manufacturers are able to provide coil protection even amidst difficult to reach areas. As a result, voids can be avoided entirely. 

Types of Coil Encapsulations: Pressurized Encapsulations

Vacuum encapsulated parts are not the only option SI Manufacturing offers customers— our team of experts also work with pressurized encapsulations. This coil encapsulation type also provides ample protection against difficult environments and corrosion. Electronic assemblies further benefit from pressurized encapsulations due to the way that added protection further improves voltage and temperature resistance as well.

Coil Encapsulation Materials

Coils can be encapsulated with several different materials, including Engineered Thermoplastic Material, Thermoset Epoxy material, or even Liquid Epoxy. Quick setting resins, in particular, are another encapsulation option which prove advantageous for orders that require quick turnaround. By employing the use of this beneficial material, customers can receive their encapsulated coils according to an expedited schedule.

Consult with SI Manufacturing to Determine if Coil Encapsulation Is Right for You

As you can see, investing in encapsulation can be the key to high functioning coil products. By maximizing structural integrity, the SI Manufacturing team produces electromagnetic parts and components for a wide variety of industries, accommodating even the harshest of work environments. If you are unsure whether or not you need to request coil encapsulation as part of your order, our team is available to consult with you to determine the most appropriate and advantageous course of action during the manufacturing process. 

Closeup,Of,Inductors,On,Stator,And,Rotor,With,Permanent,Magnet

Custom Magnetic Solutions

Custom magnetic devices are individually tailored to customer requirements. SI Manufacturing has built our entire business around being able to work alongside customers, communicating thoroughly to ensure each product is designed to specific specifications. Our custom magnetic options cover a wide range of products, including single and multiple phase transformers and specialty inductors. We invite customers to explore the ways SI Manufacturing can meet their needs by reading further about how we have already supplied countless industries with high quality custom magnetic solutions.

When Does A Designer Need A Custom Magnetic Device? 

While many people are able to find “off the shelf” products to suit their magnetic device needs, SI Mfg specifically works with customers with unique mechanical or electrical needs that require “tailor made” solutions. Often working with aerospace and defense industry projects, SI typically begins each project by designing a product that prioritizes high precision performance as well as cost efficiency. 

SI Assembly Projects

In the past SI Mfg has worked on various assembly projects. In many instances, customers come to us because they require special features for their custom magnetic devices, such as specialty termination configurations. In the case of space industry projects, SI not only produced unique assembly configurations for applications, but our design team manufactures components with such precision that the parts long outlived the expected lifespan.

Build to Print VS. Black Box

Because SI Mfg has worked with countless different customers on varying types of custom magnetic device projects, we are adaptable to every company’s individual preferences on manufacturing approaches. For example, our team has worked on both build-to-print projects and build to print projects alike. 

During build to print projects, customers come to SI Mfg with a comprehensive understanding of their own specifications, requiring little design engineering feedback. During these projects, our team follows the lead of our customers, taking into account detailed data points, such as values and tolerances for rated current, inductance, DC resistance, leakage inductance, turns ratio, primary / secondary voltage, etc. For build to print orders, SI Mfg can work from either 2D or 3D drawings when provided. 

“Black box”, or design to spec, orders, on the other hand, are projects which typically involve more input from SI’s design team. Customers who have benefited from this type of custom magnetic manufacturing service are typically those who know their base level input / output voltages and currents, but require the skills and experience of a well-rounded design team. 

Invest in the Best of Custom Magnetics Manufacturing

Because SI Mfg employs the best the industry has to offer and boasts high retention rates among our workforce, customers can rely on our company to handle every custom magnetic project with care. With a long history of customer satisfaction, there is truly every reason to partner with SI Mfg today!

Bokeh,Electronic,Circuit,Close,Up,Computer

Understanding the Responsibility of being a Sole Source

SI Manufacturing is aware that not every company operates with their customers’ best interests in mind. In fact, it is all too common for single source companies to upcharge their clients because they know that their customers are not able to obtain individual services from competitively priced sources. While the streamlined approach to manufacturing has great potential for success, it is clear that putting all of your eggs in one basket can pose significant risks.

Fortunately, SI takes the opposite approach to manufacturing, always prioritizing conscientious business practices for the sake of our clients. When equipped with a single-minded focus on customer satisfaction, sole source electronics manufacturing companies are in the unique position to optimize costs by streamlining production. Furthermore, because single source service providers reduce the need for delivery between manufacturing facilities, shipment costs are also greatly reduced.

Reliable Sole Sources Save Time

A significant benefit of working with a sole source manufacturer is that customers do not have to vet electronics manufacturers individually for every manufacturing service involved in the production of their products. Because a company like SI Manufacturing is able to complete our assemblies from start to finish, customers only need to verify the quality and dependability of one company. By minimizing the time spent researching several different sources, SI Manufacturing is able to free up our clients’ schedules, allowing them to invest their time in other areas of their business.

While in theory the single source approach eliminates the amount of time spent recruiting various service providers, there are risks associated with electronics manufacturing companies that are not prepared to be their customers’ primary service provider. Not every sole source supplier holds itself to high standards, which can result in delays and product defects. Fortunately, SI Manufacturing ensures high-quality end results by implementing extensive strategies to combat common industry hazards.

SI Manufacturing verifies the quality of the materials we work with before any electronics manufacturing services even begin. Using thorough source inspection before any material is shipped from a supplier’s facility is the first step of any project. Next, our team performs first article inspections and certifies that all materials and processes are up to industry standards. FAI is required for the first time item supplied or when a change in requirement, material, or process has occurred. Attention to detail is the key to providing the best possible electronics manufacturing services to our customers.

Operating as a Sole Source Amidst Supply Chain Disruptions

In addition to the typical factors that affect sole source operations, in recent years, there has been extensive discourse surrounding supply chain disruptions across countless sectors of business. This includes the primary industries that SI Manufacturing serves. Because of this, SI Manufacturing’s role as a sole source provider of electronic manufacturing services has become even more crucial.

Circuit Board

How Custom Magnetics Can Optimize Your Electronics Assembly

In the world of electronics assembly, high quality is the key to maximizing overall operational efficiency. With SI Manufacturing as your partner, a wide range of custom magnetic products are at your disposal, allowing for fully optimized electronics assemblies. As opposed to standard magnetic components, these custom magnetics are built according to each customer’s unique needs and requirements. Learn more about how custom magnetics impact the industry for the better and consider the ways that these products could benefit the workflow of your facilities.

What Is a Custom Magnetic Device?

Custom magnetic devices typically have standardized counterparts that customers are likely already familiar with. From transformers, to inductors, reactors, and magnetic amplifiers, SI Manufacturing is able to custom design magnetic components using fine or heavy configurations.

Custom magnetic orders can also be delivered as an assembly itself— combining components like inductors and capacitors together to create a complete custom magnetic assembly. Unlike generic “off the shelf” magnetic devices, these custom projects can be fitted with unique mounting features and configurations to ensure the highest degree of functional efficiency is achieved during assembly use.

When To Order A Custom Magnetic Device?

While it is true that standard magnetic devices can often be purchased at lower upfront costs than custom magnetic devices, there are many instances when investing in custom magnetic devices proves to be the most cost-effective option.

Optimizing for Cost and Material Availability

The main reason for a design engineer to choose to order a custom magnetic device is when there is simply no alternative that matches the exact mechanical or electrical requirements necessary. However, even in instances where a standard off the shelf magnetic product can technically be utilized for an electronic assembly, design engineers may still opt for a custom order if the assembly can be optimized to use more widely available materials.

Especially in recent years, as supply chain disruptions have impacted entire global industries, it has become important to invest in flexible manufacturing strategies. Not only are magnetic alloys often costly, but growing demands can also impact the speed at which these materials are available. Fortunately, custom magnetic devices offer a solution.

While manufacturers still must work with magnetic alloys, as opposed to more common materials, such as steel or aluminum, custom magnetic projects can be designed to reduce the material needed to create a functional device. This ultimately reduces costs and enables manufacturers to better avoid inconvenient production delays.

Finding a Manufacturer for the Best Custom Magnetic Devices

Once you have determined that custom magnetic devices are necessary to optimize your electronic assembly, the next step is to find a reliable manufacturer that is able to meet your custom magnetic device manufacturing needs. Initially, it is important to verify that the magnetic device manufacturer has extensive experience working with your specific industry. For example, SI Manufacturing boasts years of experience working with medical, aerospace, defense, and automotive customers, making our company an ideal resource for many potential customers.

Furthermore, it is crucial to verify that your manufacturer is properly certified to carry out custom magnetic manufacturing projects. Once you have determined that a company is dependable and reputable among third-party sources, you can begin placing your custom magnetic order and reap the benefits of optimized electronic assemblies!

Importance of People

Importance of People

At SI Manufacturing, we pride ourselves on prioritizing the needs of our workforce. We understand that our employees go to work everyday to provide for themselves and their families, so we take great efforts to create a healthy work environment for them to succeed in. Congeniality is a core value of our company, and we continue to see the positive impact this approach to business has had on our employees and customers alike.

Our Place in Space

Our Place in Space

SI Manufacturing has been involved in the Space industry since the beginning, and has recently expanded our business to keep up with the ever-evolving needs of the space industry. Today, the space industry makes up 20% of our business, and our continued dedication to problem solving has had far-reaching success, situating SI Manufacturing as the ideal partner for innovative projects.

What We’re Working On

What We're Working on

The SI Manufacturing facility is a crucial asset to our company, as it is where we conduct everything from manufacturing and processing, to test and inspection operations. Our facility prioritizes a streamlined production process in order to provide our customers with the best possible service. When you partner with SI Manufacturing, our facility is dedicated to finding easier, lower-cost manufacturing solutions that meet your unique needs.

Women in Leadership

Women in Leadership

At SI Manufacturing, we believe that a diversified workforce is what leads to greater industry success and innovation. We organize our business according to this belief, promoting several women to supervising and leadership roles, and have already seen the benefits. With an average 10-year tenure at our company, the women in leadership at SI Manufacturing propel our company into the future of manufacturing.