Custom u cores anyone?

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So.. anyone who has looked for Stan's U cores knows they cannot be found! (If someone has found a source, please let me know) Their may be substitutes, but I feel the best plan of action would be to pull together and order custom cores to our specifications. I have all of the sizes from Don, but I need to know what you guys think about the material they should be made of, permeability... ect? Remember, it needs to work between 0 and 10 khz
 
I'm already tried Adams magnetics, but they don't actually make the cores themselves and they said I would have to order around 1000. so that’s not really an option. I'll be contacting some other companies as soon as I get a better idea of what we need? and once I know that other people are interested. The price for you guys would be cost plus shipping, nothing extra
 
 
 
 

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it seems that having a custom core made is more difficult then I thought, I'm still checking into more company's, if anyone knows a good site to buy U cores please post them.

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A friend of me made 3 pairs for testing - 2 of them was sent to Outlaw and Tony. We are still looking into the permeability and induction of the cores. The price is high for one sett, but after all,they are custom made. When we have the correct value, I recon that there will be made a few of them in the same fashion. But in the end, a production mold must be made, also something that I've investigated and have offers on.

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Cool! Hopefully I can get my hands on one when that day comes

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Has anyone tried to find a place to buy ferrite
in sheets? looking at stan's and u core's
that others have done they look like they were
cut from a sheet.

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Has anyone tried to find a place to buy ferrite
in sheets? looking at stan's and u core's
that others have done they look like they were
cut from a sheet.

Nope....
Ferrite is nasty stuff to cut, but already know that, ill guess...

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Here are a few images from the process used to cut our very first U cores - for your pleasure 
As I mentioned, it takes several attempts to do this, but we learned and have refined the method. The cost is always going to be higher then using a mold to cast the cores. I am letting you know that we can manufacture these types of cores, but this is foremost used only to get the correct value and getting the correct value is not the most easy task at hand. But we are getting there.

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glad someone is doing this!! they look great