How Magnets Are Created

The magnet manufacturing process takes approximately 4-6 weeks from start to finish, undergoing a number of steps to ensure our customers are provided with the best quality magnets possible. We are experts in every step in the process, from mining all the way to your application. Take a look at the page to learn what stages your magnet will go through or even download our infographic!

(Please note times are given as approximations and all orders can vary.) 

1. Mining 

The manufacturing process begins with the mining for the raw materials required to produce rare earth magnets.

2. Strip Casting

Strip casting is a rapid processing technique in which the molten material is poured into a shell mould or larger green sand moulds. As the molten metal cools, the shell moulds and starts to burn and by the time the magnet is cold the shell is almost disintegrated.

3. HDDR

Hydrogenation disproportionation desorption recombination (HDDR) process is the means of producing bonded magnets from used NdFeB-type sintered magnets with compositions.

4. Milling

After the liquid alloy has been poured and cooled with water it will be broken down and milled to produce tiny particles.

5. Pressed

The super-fine powder will then be pressed in a mould while simultaneously the magnetic energy is applied to the mould. This is done through the use of a coil wire which acts as a magnet when electrical current is passed though. As the mixture is pressed the magnetism is locked in.

6. Sintering

Once the powder has been pressed it can then be sintered in a furnace in a hydrogen atmosphere at over 1200°C. This process fuses all the pressed particles together to form one magnet.

7. Performance Testing

There are several measurements which all contribute to a magnet’s strength in different ways whether this be its pulling force or magnetic field strength. Each of these factors will have to be tested and measured, you can see how each of these tests are carried out here.

8. Machining

This stage is where the raw magnets are machined into their desired shape, however due to some magnets’ strength this requires a diamond plated cutting tool.

9. Surface Treatment

The last step before remagnetising is vital because certain magnets are prone to breaking and chipping - they must be coated, cleaned, dried, and plated. Our most common is a nickel-copper-nickel mixture, but our magnets can also be coated in other metals, PTFE or even rubber.

10. Magnetised 

Once plated, the finished material is then remagnetised - this will mean placing it inside a coil which when electric current is passed through, produces a magnetic field three times stronger than the required strength of the magnet.

11. Packing

The final stage of the process in which our team of experts carefully pick and pack the magnets in the correct fashion so they can be shipped safely and arrive in a perfect condition to our customers to be used in thousands of different scenarios and applications all over the globe.

Based on the data presented above, the process takes approximately 18-33 days. Please note times can vary per magnet.

 

Want a downloadable PDF Infographic of this information? Click the link below.

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