bespoke ferrite machining facility Learn More The Ferrite Gateway Machine Shop offers customers a complementary service to provide custom gapped and machined ferrite cores from our specialist UK facility. Gateway already stocks a vast range of ‘standard’ gapped cores as well as a comprehensive portfolio of ungapped ferrite cores. The machine shop facility now gives customers across Europe the opportunity to have cores gapped to bespoke inductance, AL or dimensional specification without the hassle of high minimum order quantities or extended factory lead times. The Machine Shop specialises in machining custom geometry ferrites utilising our exclusive channel for ferrite blocks from some of the biggest names in ferrite. If You Can Dream It, We Can Machine It! Tolerances AL and Inductance Values Down To +/-1% Dimensional Values Down To +/-0.005mm General Machining To +/-0.05mm CanDo Solutions Get In Touch Gateway works with customer partners nationally and internationally to fulfill our customers demands both with supply and design support. If required we can offer our customers extended services with UK based professional experts to offer a complete design and manufacturing solution. Bespoke coil former: - Moulded in pin - Machine - 3D printed Winding service Transformer redesign Transformer manufacturer Assembly Moulded and machined parts Capabilities 3-Axis NC Surface Grinder Bespoke 3-Axis CNC Milling Machines 5-Axis CNC Milling Machine Ferrite Machining Tools Wireless Probing System 3D Printer Lapping Machine Ultrasonic Cleaner Next Prev Equipment Tools & Stock Process & Quality One of the Largest Ferrite Stockists in Europe Offering over 700 cores from our UK warehouse, Gateway is one of the largest ferrite stockists in Europe. Our stock profile is built to ensure we cover all customer applications including power, signal and EMI for both low and high frequency applications. Stocking material from Ferroxcube, TDK (EPCOS), Fair-Rite and Mag Inc ensures quality is never an issue for our customers. Gateway also stocks an exclusive range of blocks from TDK (EPCOS) and Ferroxcube. The range of stock comprises of the latest materials from the leading ferrite manufacturers. The Machine Shop has close links with both factories at TDK and Ferroxcube, this allows us to work with the technical departments to create new materials that are designed specifically for our customers application, these can then be pressed into blocks and machined. Tooling Gateway works exclusively with UK tooling manufacturers to produce the specialist tooling required for machining ferrite. All machine tools are produced to Gateways exact specification, a specification built on years of knowledge, experience and most of all Research & Development. This allows The Machine Shop to offer a dynamic and flexible response to our customers requirements and provides a solid foundation to meet the most demanding of designs allowing us to machine the most challenging geometries whilst maintaining lead times as short as one week for custom geometry cores. Workholding Gateway uses the latest technology to continuously refine its work holding techniques. In turn this allows us to push our machining capabilities and meet the most demanding of requirements. The nature of ferrite dictates that standard mechanical work holdings cannot be used. The Machine Shop uses magnetic workholdings as the foundation of all jobs. These magnetic work holdings are customized and supplemented through additive and subtractive machining techniques to ensure we keep costs and delivery times down to an absolute minimum for our customers. Materials TDK N49 Ferrite N95 Ferrite N97 Ferrite N92 Ferrite N27 Ferrite T46 Ferrite T38 Ferrite Ferroxcube 3E27 Ferrite 3C97 Ferrite 3F46 Ferrite 3F4 Ferrite 3E6 Ferrite 3C96 Ferrite 3F36 Ferrite 3C92 Ferrite 4F1 Ferrite 4PDP Ferrite 4PD4 Ferrite 3C90 Ferrite 3C94 Ferrite 4B1 Ferrite 4B2 Ferrite 3C95 Ferrite Magnetics Inc J Ferrite P Ferrite R Ferrite T Ferrite KOOL MU Powder MPP Powder X FLUX Powder Kemet (Tokin) BH1T Ferrite The Machine Shop has developed exacting standards and test procedures to ensure everything that is shipped meets the specification outlined in the drawing. We stock a large range of standard test coils which are all wound to ensure the full winding area is filled with 100 turns of wire; ensuring the winding is evenly distributed over the gap which increases test accuracy. As well as standard test coils, The Machine Shop can use customers test coils and test to their exact specification. Substantial investment has been made in a wireless probing system that allows measurements to be taken in three dimensions with up to 0.001mm repeatability. The probing system is driven by our CNC system and provides customers with absolute measurements that they can rely on. Test and Measure The Machine Shops standard test procedure is to sample batch test the finished cores to ensure the specification is met. The test results are electronically stored against the works order job and can be recalled at any stage. The Machine Shop can offer 100% testing and can also offer a First Article Inspections service, based on our own standard template or adjusted to match the customers test requirements. We are able to machine to the following tolerances: AL and inductance values down to +/-1% Dimensional values down to +/-0.005mm General Machining to +/- 0.05mm Every job that passes through The Machine Shop will have a dedicated CAD drawing, drafted by one of our team of trained engineers, to meet the specification requirements of the customer. After customer approval of the drawing, and any agreement on First Article Inspection samples, the job will be committed to The Machine Shop’s schedule. CAD The Machine Shop schedule planning is maintained with the Production Works Order system embedded in our operating system. After drawing approval is received, and the works order is raised, the customer will receive an indication of job completion dates based on machine loading. The Gateway operating system has live updates for Sales staff so that they can monitor the progress of Machine Shop jobs, and report any changes to schedules where appropriate. In some cases, capacity adjustments may be possible to expedite urgent customer requirements. Planning During the machining process coolant is used to control temperature effects, reduce tool wear and control airborne particulates. After machining, the ferrite is often left with a deposit of ferrite sediment that needs to be removed. The ultrasonic cleaning bath is used to remove the ferrite sediment using environmentally friendly cleaning agents, and then the cores are air treated at room temperature prior to packaging. All ferrite cores are securely packaged in polystyrene shipping containers and/or secure vacuum packaging to avoid damage when in transit. Standard or customer bespoke labelling will then be affixed to the packaging and relevant test documentation will accompany each batch of material supplied. Ultrasonic Cleaning and Packaging Cutting slots in parts are useful for allowing an access point for a cable to enter the centre of the part. They are most useful for pot cores that don’t have an opening in the outer limbs for cables to exit. Our custom tooling is used when machining which allows for a precise slot to be achieved. Slot cutting Chamfers and fillets reduce the number of sharp edges on a core – they are often found on square parts that may need to fit inside of a round bobbin. These processes are also useful for reducing the degradation of the insulator around the wire that may be wound straight onto the core, as they reduce the chance of the wire being damaged, or even broken, upon installation. Profile and contour machining - chamfers and fillets With the use of our 3-axis machines and specialist tooling, we are able to drill holes into ferrite blocks. These holes can be bored out to the desired size, allowing tighter tolerances to be achieved. Holes can be useful for EMC applications where the distance between the ferrite and the conductor can have a direct impact on the attenuation levels available. Holes are also used for mounting and can be used to insert temperature sensors into the centre of the core to allow the user to record the core temperature. Hole cutting - small drill holes, large bores CNC (Computer Numerical Control) machining allows us to generate a program which our machines can follow to create the desired part. 3-axis machines operate on the x-y-z planes which allow unique designs to be produced, however 5-axis machines have the additional benefit of an a-b axis – this allows for more intricate parts to be created from a single program. The added a-b axis allows for the stock to be moved, as well as the tooling. We have refined our machining techniques to ensure we produce the highest quality parts. Full 3/5-axis CNC machining Custom core geometries can be machined from blocks with help from our 3-axis machines and close partnerships with suppliers of raw material – we work with some of the biggest names in ferrite, including TDK, Ferroxcube, Fair-Rite and Magnetics Inc. Stocking a wide range of block sizes allows us to choose the most appropriate material to machine each custom geometry. Our motto is “If you can dream it, we can machine it” and we always aim to exceed customer expectations. This is a cost-effective alternative to paying for a mould tool and pressing/sintering the custom geometries which can cost £1000’s per tool, we also offer rapid turnaround. Custom core geometries from blocks A toroid can be split into two pieces, which allows the part to be used in places which already have high-voltage wires installed and can’t be removed easily. Splitting the toroid enables each half to be placed on either side of the wire to be joined together. Our custom-made jigs mean the parts can be held in place whilst machining in order to reduce any chipping or fracturing. Custom cutting discs also enable the toroids to be cut using our 3-axis milling machines. Toroid splitting We can add small air gaps into toroids using our dedicated tooling, gaps as small as 0.8mm up to large gaps, this is useful for changing the inductance value of the toroid and is popular in sensor applications. Toroid air gaps Adding a centre limb gap allows us to tune the core’s inductance value to the customer’s requirement. The larger the gap the smaller the inductance value of the core. Gaps are applied to the centre limb to control leakage and offers a vast improvement on mechanical gapping (adding material between all 3 limbs). The higher inductance values can be influenced by very small imperfections or changes in dimensional gap; therefore, it is crucial to have high precision machinery to allow us to hit tight tolerances down to +/-1% on inductance and +/-0.005mm on dimensional gaps. Gapping a core can also influence the Bsat figure by pushing this higher. Centre limb gaps - AL, inductance and physical gaps We can machine rods to the length required by a customer – to do this, we use a specific cutting wheel which cuts through the excess rod and leaves a tidy finish on the machined rod. With the aid of custom jigs, we are able to machine rods to any length required. This enables the final part to fit a variety of applications – small or large, achieving the desired effect. Rod machining - cutting, length reduction Ferrite gluing is a useful method of achieving parts that can’t be made from just one block of material. This increases the scale of parts that can be created and enables customers to create truly bespoke pieces. We also use two different types of glue, with one being able to withstand higher temperatures, which again increases the types of projects that we are able to undertake. Ferrite gluing Lapping is a process that allows us to create a perfectly flat face. This is done through removing material from the surface of the ferrite to reduce the residual air gap. This technique allows us to increase the Inductance value of the core, we can further increase this by creating a mirror finish on the mating faces. Lapping and mirror finish Next Prev Scroll Through Our Many Capabilities Overview Capabilities Process & Quality Gallery Contact Us More Click Here To View Our Gallery Centre limb gaps - AL, inductance and physical gaps Adding a centre limb gap allows us to tune the core’s inductance value to the customer’s requirement. The larger the gap the smaller the inductance value of the core. Gaps are applied to the centre limb to control leakage and offers a vast improvement on mechanical gapping (adding material between all 3 limbs). The higher inductance values can be influenced by very small imperfections or changes in dimensional gap; therefore, it is crucial to have high precision machinery to allow us to hit tight tolerances down to +/-1% on inductance and +/-0.005mm on dimensional gaps. Gapping a core can also influence the Bsat figure by pushing this higher. Profile and contour machining - chamfers and fillets Chamfers and fillets reduce the number of sharp edges on a core – they are often found on square parts that may need to fit inside of a round bobbin. These processes are also useful for reducing the degradation of the insulator around the wire that may be wound straight onto the core, as they reduce the chance of the wire being damaged, or even broken, upon installation. Hole cutting - small drill holes, large bores With the use of our 3-axis machines and specialist tooling, we are able to drill holes into ferrite blocks. These holes can be bored out to the desired size, allowing tighter tolerances to be achieved. Holes can be useful for EMC applications where the distance between the ferrite and the conductor can have a direct impact on the attenuation levels available. Holes are also used for mounting and can be used to insert temperature sensors into the centre of the core to allow the user to record the core temperature. Full 3/5-axis CNC machining CNC (Computer Numerical Control) machining allows us to generate a program which our machines can follow to create the desired part. 3-axis machines operate on the x-y-z planes which allow unique designs to be produced, however 5-axis machines have the additional benefit of an a-b axis – this allows for more intricate parts to be created from a single program. The added a-b axis allows for the stock to be moved, as well as the tooling. We have refined our machining techniques to ensure we produce the highest quality parts. Custom core geometries from blocks Custom core geometries can be machined from blocks with help from our 3-axis machines and close partnerships with suppliers of raw material – we work with some of the biggest names in ferrite, including TDK, Ferroxcube, Fair-Rite and Magnetics Inc. Stocking a wide range of block sizes allows us to choose the most appropriate material to machine each custom geometry. Our motto is “If you can dream it, we can machine it” and we always aim to exceed customer expectations. This is a cost-effective alternative to paying for a mould tool and pressing/sintering the custom geometries which can cost £1000’s per tool, we also offer rapid turnaround. Toroid splitting A toroid can be split into two pieces, which allows the part to be used in places which already have high-voltage wires installed and can’t be removed easily. Splitting the toroid enables each half to be placed on either side of the wire to be joined together. Our custom-made jigs mean the parts can be held in place whilst machining in order to reduce any chipping or fracturing. Custom cutting discs also enable the toroids to be cut using our 3-axis milling machines. Toroid air gaps We can add small air gaps into toroids using our dedicated tooling, gaps as small as 0.8mm up to large gaps, this is useful for changing the inductance value of the toroid and is popular in sensor applications. Rod machining - cutting, length reduction We can machine rods to the length required by a customer – to do this, we use a specific cutting wheel which cuts through the excess rod and leaves a tidy finish on the machined rod. With the aid of custom jigs, we are able to machine rods to any length required. This enables the final part to fit a variety of applications – small or large, achieving the desired effect. Slot cutting Cutting slots in parts are useful for allowing an access point for a cable to enter the centre of the part. They are most useful for pot cores that don’t have an opening in the outer limbs for cables to exit. Our custom tooling is used when machining which allows for a precise slot to be achieved. Ferrite gluing Ferrite gluing is a useful method of achieving parts that can’t be made from just one block of material. This increases the scale of parts that can be created and enables customers to create truly bespoke pieces. We also use two different types of glue, with one being able to withstand higher temperatures, which again increases the types of projects that we are able to undertake. Lapping and mirror finish Lapping is a process that allows us to create a perfectly flat face. This is done through removing material from the surface of the ferrite to reduce the residual air gap. This technique allows us to increase the Inductance value of the core, we can further increase this by creating a mirror finish on the mating faces.

Our Work 3D Machined Ferrite Ferrites For Busbars Machined Ferrite From Block CNC Machined Antenna Ferrites Machined E Core Machined and Glued Toroids Glued Ferrite U Core Machined Ferrite Ferrite PM Core Ferrite E Cores With Centre Limb Holes Ferrite E Core With Gapped Centre Limb Machined Ferrite Ring Distributed Ferrite Air Gaps Cut Ferrite Toroid EMC Ferrite Machined From Block Pair of E Cores With Centre Limb Gap Large Machined and Glued Ferrite E Core Glued Ferrite Chamber Group of Hyper VSN Ferrites OTT Ferrites Machined Ferrite Rods Ferrite Rings Ferrite Toroids With Machined Slot Machined Ferrite Cores