Most of a lifetime ago I was a component engineer at Collins Radio, and
one of the products I was responsible for was a small ferrite core. The
manufacturer's rep explained the manufacturing process to me, which is
basically like making a ceramic mug, and likened it to baking a cake.
The process variables are many and significant, and even with automation
the end result varies a lot.
ChatGPT provided a summary of the potential process considerations:
https://chatgpt.com/share/69095b41-ed34-8001-83ba-6c412e5e473e
Dave AB7E
On 11/3/2025 4:40 PM, Jim Lux wrote:
20-25% is actually what Fair-rite gives as a tolerance for their cores (at
least for the EMI suppression family) - Chip beads are 25%
So if you've measured 20% variation, that's probably within spec.
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