A More Intelligent Process, Simplified
From initial design to quality assurance, Buckley Systems applies more than 40 years of real-world experience to build and refine our process from the ground-up to reinforce the integrity and performance of every product.
Physics Design
We are leaders in electromagnet design, specializing in magnetic modeling.
Whether validating the harmonic errors of synchrotron magnets, or developing the ion optics of a spectrometer, you can be confident your magnetic components will perform when needed most.
We’ve developed our own field mapping equipment, including hall probe test beds, rotating coils and stretched wire devices. We use Opera finite element modelling codes, including static and time varying magnetic solvers.
- Our Physics Team specializes in the design of all types of electromagnets. They are ready to tackle your demanding application.
- We partner with scientific consultants with expertise in ion optics, beamline design, ion sources, beam diagnostics and vacuum systems.
MECHANICAL DESIGN
We take a collaborative approach where we co-design—or even lead the design—to meet challenging project requirements.
We build not only to be fit-for-purpose, but also to exceed your expectations.
Continual research and development is how we work, including our ability to design and build custom-made machinery, winding jigs, formers, impregnation molds, gauges and testing equipment in-house. We continually suggest improvements, adapt to your schedule and optimize outcomes.
- We have a full in-house team of mechanical engineers.
- Our engineering team is highly integrated with our manufacturing, physics and magnetic testing teams, empowering effective decisions in manufacturability, efficiency and repeatability.
Manufacturing
From the smallest to the largest electromagnet, we provide unmatched manufacturing capability with accuracy and dependability through a strong blend of people and precision machinery.
Keeping manufacturing in-house delivers the agility and dependability you need to keep achieving your own project objectives.
We machine, manufacture coils, assemble and test in-house, providing you greater quality control, consistency and performance. We’ve also pioneered many advances in electromagnet manufacture, including laser cutting of laminations and EDM wire cutting of multipole pole profiles.
- We maintain flexible and scalable operations and implement robust risk management systems to ensure reliable supply, consistent quality and continuity.
- Vertical integration means you can deal with one partner through every stage from design to delivery.
MACHINING
With more than 45 CNC machining centers, spread over an 18,000m2 workshop, we have one of the largest machine shops in the Southern Hemisphere. Our investment in machining capability is about more than just purchasing the largest, most advanced CNC equipment–we also employ and develop a large team of highly skilled operators. The depth of this machining capability streamlines manufacturing and minimizes risk.
COIL MANUFACTURING
Our coil shop has developed robust and consistent techniques for this specialized product. Your coils will be manufactured with extensive knowledge of materials and forming, resins and fillers, vacuum impregnation and tooling. That means you get proven quality, longevity and consistency.
We have manufactured a huge range of different coil types. Whether your copper coil design is basic or exotic, grams or tons, from one-off prototypes to production runs, we have the capability and capacity to deliver.
Auxiliary
ManufacturingOur advanced auxiliary processes ensure precision, reliability, and superior product quality across every stage of production. Our process and team have reached a high state of refinement.
- Weld Bay: Equipped for robotic MIG, TIG, and spot welding, delivering strong, reliable welds with high dimensional accuracy.
- Plating: Offers protective and vacuum ready metal finishes that enhance corrosion resistance and product longevity.
- Laser Processing: High-precision laser cutting and engraving for intricate designs and tight tolerances.
- Lamination: Multi-layer bonding for improved material strength, insulation, and surface finish.
- Paint Shop: Automated and manual painting systems providing durable coatings with consistent color and finish.
- Testing: Our comprehensive in-house testing facilities ensure every component meets the highest performance and quality standards. The temperature-controlled testing facility is equipped with helium leak detection devices, calibrated flow meters, and pressure gauges.
- Assembly: Our streamlined assembly lines, operated by skilled technicians in a purpose-built environment, ensure efficient and high-quality product integration every time.
- Packing: We have our own packing workshop that designs and builds shipping crates using heat-treated New Zealand pine and custom-made securing brackets. Larger magnets are shipped in steel crates. Environmentally friendly materials are used wherever possible. Where required, we can seal magnets in nitrogen-filled bags for additional corrosion protection.
QUALITY
Buckley Systems builds repeatable, consistent performance into every product through a comprehensive Quality Management System (QMS) certified to ISO 9001.
Our QMS provides a structured framework for documenting, standardising, and continually improving our processes across the full product lifecycle – from design and development through procurement, manufacturing, assembly, testing, and ongoing support. By embedding quality into every stage, we ensure compliance with customer, regulatory, and industry requirements while driving continuous improvement across the business.
Our Quality Department carries out thorough in-process inspections, final product verification, and release validation prior to dispatch, ensuring every product meets defined quality and performance specifications.
To support this, our team uses advanced metrology and inspection technology – including Coordinate Measuring Machines (CMMs), laser trackers, and 3D laser scanners for fiducial point identification and dimensional verification – alongside a full suite of calibrated precision measuring instruments. This enables high-accuracy inspection, verification, and traceability across all our manufacturing processes.
Customer Engagement
We have a commitment to clear communication with our customers and keep them informed and up-to-date throughout a projects lifecycle and beyond. A project manager is assigned to each customer and acts as the first point of call for direct communication with customers through face-to-face communication, Email, phones and via online meetings.