Unfortunately a punch and die won’t work because the ferrite we’re using are sintered plates that would crack apart. I didn’t realize how hard they were, I’m used to working with soft ferrites. Harder is better for our application though because it won’t develop cracks and will reinforce the PCB. Plus you get more ferrite per ferrite! (magnetic permeability). Jammy kept referring to the assembly jig as a “plate” earlier which probably confused things.
If we do a production run of these where we would need economies of scale the part sourcing and techniques involved in this project will scale well. We’d only ever be making hundreds