The Ferrite Machine Shop

If You Can Dream It, We Can Machine It!

The Ferrite 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 Ferrite Machine Shop facility now gives customer across Europe and USA 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 Ferrite Machine Shop specialises in machining custom geometry ferrites utilising our exclusive channel for ferrite blocks from some of the biggest names in ferrite.

Tolerances

AL & Inductance Values

+/- 1%

Dimensional Values

+/- 0.005mm

General Machining

+/- 0.050mm

Capabilities

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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.

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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.

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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 £1000s per tool. We also offer fast turnaround.

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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.

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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.

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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.

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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.

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CNC 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.

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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.

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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.

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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.

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Annealing ferrite cores after machining is an important step in enhancing their magnetic performance, particularly for high-frequency applications where efficiency and stability are critical. The machining process enables precise shaping and tight tolerances, and annealing complements this by optimising the material’s magnetic characteristics. Through controlled heat treatment, the crystal structure and magnetic domains are refined and stabilised, supporting improved permeability and reduced core losses. For high-frequency materials, this results in better Q factor, enhanced thermal performance, and consistent behaviour across the operating range. Overall, annealing ensures that precision-machined ferrite components deliver the highest level of performance and reliability in demanding applications.

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Laser engraving ferrite cores provides a reliable and permanent solution for marking part numbers, ensuring clear identification throughout the product’s lifecycle. Ferrite materials are inherently hard and abrasive, which can make traditional marking methods less consistent over time. In contrast, laser engraving uses a non-contact process to precisely etch the surface, creating clean, high-contrast marking that remain legible even in demanding handling and operating environments. This approach supports traceability, improves quality control, and eliminates the need for consumables, delivering a consistent and durable marking solution ideally suited to precision ferrite components used in high-performance applications.

Services

CAD

Every job that passes through The Ferrite 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.

Planning

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.

Measurement

Offering over 700 cores from our UK warehouse, The Ferrite Machine Shop 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 high and low frequency applications. Stocking material from Ferroxcube, TDK (EPCOS), Fair-Rite and Magnetics Inc ensures quality is never an issue for our customers.

The Ferrite Machine Shop also stocks an exclusive range of blocks from Ferroxcube, Fair-Rite, Magnetics Inc and TDK. The range of stock comprises of the latest materials from the leading ferrite manufacturers.

The Ferrite Machine Shop has close links to factories, allowing us to work with the technical departments to create new materials that are designed specifically for your applications. These can then be pressed into blocks and machined.

Testing

Ultrasonic Cleaning & Packaging

Custom Packaging

Gallery

Ferrite Materials

One of the Largest Ferrite Stockists in Europe

Material	Initial Permeability - μi	Flux Density - Bsat (mT) @25°C	Curie Temperature - Tc (°C)	Frequency Range (MHz)	Block Size - W/L/H (mm)
3E27	6000	~430	150	20	104/66/15
3C97	3000	~530	220	0.5	120/120/60
					160/86/36
					120/120/38
3F46	750	~520	280	1-3	50/50/15
3F4	900	~410	220	1-2	100/100/22.5
3F4	900	~410	220	1-2	100/100/15
3E6	10000	~460	130	<15	50/50/30
3C96	2000	~500	240	<0.4	120/120/38
3C96	2000	~500	240	<0.4	40/71/6
3F36	1600	~530	230	<0.3	100/100/17
3C92	1500	~540	280	<0.2	72/64/12
3C92	1500	~540	280	<0.2	120/120/38
4F1	80	~320	260	4-10	50/50/25
4PDP					50/50/25
4PD4					50/50/25
3C90	2300	~470	220	<0.2	100/85/25
3C94	2300	~470	220	<0.3	100/90/4
4B1	250	~360	250	300-1000
4B2	250	~360	335	<5
3C95	3000	~530	215	<0.5
3N1T	1800	~420	150	<300	79/76/30
3N2	3000	~410	150	<300	79/76/30
3N3	1250	~520	200	<30	79/76/30
3N4	2500	~530	200	<30	79/76/30
3N5	6000	460	150	<30	79/76/30
3N10	8000	460	130	<30	79/76/30
4C65	125	380	350	<15	104/66/12
4A11	850	340	125	30-1000	50/50/25
3C98	2500	530	230	<0.4	70/56/12

Material	Initial Permeability - μi	Flux Density - Bsat (mT) @25°C	Curie Temperature - Tc (°C)	Frequency Range (MHz)	Block Size - W/L/H (mm)
31	1500	360	130	0.1-300	108/108/21
44	500	300	160	25-300	106/106/21
52	250	420	250	200-1000	106/106/17
61	125	250	300	200-2000	113/133/21
67	40	230	450	5-15	114/114/21
75	500	480	150	<30000	108/108/21
78	2300	480	200	<2500	108/108/21
79	1400	460	225	0.3-0.75	103/103/17
80	600	470	300	1-4	103/103/17
95	3000	500	220	<200	108/108/21

Material	Initial Permeability - μi	Flux Density - Bsat (mT) @25°C	Curie Temperature - Tc (°C)	Frequency Range (MHz)	Block Size - W/L/H (mm)
J	5000	430	145	<0.7	104/66/18.4
P	2500	470	210	<1.8	104/66/18.4
R	2300	470	210	<1.8	104/66/18.4
T	3000	530	220	<1.5	104/66/18.4

Material	Initial Permeability - μi	Flux Density - Bsat (mT) @25°C	Curie Temperature - Tc (°C)	Frequency Range (MHz)	Block Size - W/L/H (mm)
K1	80	310	400	1.5-12	155/110/23
N49	1500	490	240	0.3-1	155/110/23
					155/60/22
					155/110/23
N88	1600	510	260	0.025-0.5	155/110/23
N95	3000	525	220	0.025-0.5	125/100/20
N95	3000	525	220	0.025-0.5	155/110/23
N97	2300	510	230	0.025-0.5	155/110/23
N92	1500	500	280	0.025-0.5	140/71/30
N27	2000	500	220	0.025-0.15	155/110/30
T46	15000	400	130	0.001-0.1	66/31/13
T46	15000	400	130	0.001-0.1	25/25/8
T38	10000	430	130	0.001-0.1	66/31/13

Material	Initial Permeability - μi	Flux Density - Bsat (mT) @25°C	Curie Temperature - Tc (°C)	Frequency Range (MHz)	Block Size - W/L/H (mm)
BH1T	3000	520	220	>1	100/100/12
					100/100/20
					100/100/4
					100/100/8
					150/100/5
					240/60/20
					240/60/5

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The Ferrite Machine Shop