Rare Earth Magnet Manufacturing.

Characteristics of rare earth magnets – rare earth magnets can store far more energy than conventional magnets, enabling parts, devices or equipment to be miniaturized in response to recent market trends. Rare earth magnets are utilized where high levels of magnetic force or energy are required. The two most used rare earth alloys are neodymium (NdFeB) and samarium cobalt (SmCo). Additional benefits of rare earth magnets are that they reach magnetic energies well above hard ferrites and alnico, and they permit a much smaller magnet to be used to create a like force. The most well known example was the application of NdFeB magnets in the starter motor for GM trucks which effectively reduced the size and weight of the starter motor by two thirds.

• NdFeB - high coercivity (high resistance to being demagnetized). NdFeB also has a high saturation magnetization giving NdFeB ability for storing large amounts of magnetic energy. NdFeB magnetics are produced as injection molded magnets which permits other components, for example, a steel shaft to be insert molded. For higher energy requirements (above 5Mgo), NdFeB alloy must be sintered.
• SmCo - Samarium Cobalt is often used in micro motor applications such as camera motors. Cobalt is indeed one of the “rarer” rare earth elements and its price can fluctuate dramatically resulting in the variance of the cost of the end magnet.

Flexible Bonded NdFeB 

Grade: FBND-500 

TyTek’s FBND-500 magnets are flexible, rubber-like, bonded NdFeB composite magnets that combine superior magnetic properties with flexibility. This material is highly resistant to demagnetization, and it can be manufactured in cut pieces or continuous lengths. Rubber bonded magnets utilizing NdFeB powders are produced in conjunction with quality natural rubbers or synthetic rubbers. The compound of rubber materials and magnetic powder is then extruded in a die to the desired cross sectional geometry. This process yields good dimensional characteristics with consistent, homogeneous magnetic properties and cost effective application. Standard as-formed dimensional tolerances are typically ±.005" on thickness, ±.015" on width, and ±.015" or ±0.5%, whichever is greater on length. Tighter tolerances are negotiable.

Typically, the applications for FBND-500 include brushless DC motors, stepper motors, speed sensors, position sensors, high output encoders, and high end xerographic applications.

Grade: FBND-650 

The magnets TyTek produces in FBND-650 are flexible, rubber-like, bonded NdFeB composite magnets that combine superior magnetic properties with flexibility. These materials are highly resistant to demagnetization, and can be manufactured in cut pieces or continuous lengths. Rubber bonded magnets utilizing NdFeB powders are produced in conjunction with quality natural rubbers and/or synthetic rubbers. The compound of rubber materials and magnetic powder is then extruded in a die to the desired cross sectional geometry. This process yields good dimensional characteristics with consistent, homogeneous magnetic properties that provide cost effective applications. Standard as formed dimensional tolerances are typically ±.005" on thickness, ±.015" on width, and ±015" or ±0.5%, whichever is greater on length. Tighter tolerances are negotiable.

Typical applications include brushless DC motors, stepper motors, speed sensors, position sensors, high output encoders, and high-end xerographic applications

Injection Molded NdFeB 

Grade: IMND-550 

Injection molded magnets produced in IMND-550 demonstrate excellent properties and outstanding performance combined with exceptional dimensional tolerances. Bonded magnets utilizing NdFeB powders are produced in conjunction with quality thermoplastic resins. The compound of thermoplastic resin and magnetic powder is then injection molded. This process yields a dimensionally precise part with consistent high magnetic energy. Dimensional tolerances are typically ±.003"/inch or ±.002" whichever is greater. Tighter tolerances are negotiable.

The typical applications for these magnets include torque drives, airbag crash sensors, fractional HP motors, generators, speed sensors, air-core bobbin gages, encoders, and stepper motors.

Grade: IMND-600 

Magnets produced in TyTek’s Grade IMND-600 deliver excellent properties and outstanding performance, both combined with exceptional dimensional tolerances. Bonded magnets utilizing NdFeB powders are produced in conjunction with quality thermoplastic resins. The compound of thermoplastic resin and magnetic powder is then injection molded. This process produces a dimensionally precise part with consistent high magnetic energy. Dimensional tolerances are typically ±.003"/inch or ±.002" whichever is greater. Tighter tolerances are negotiable.

Typical applications for IMND-600 include torque drives, airbag crash sensors, fractional HP motors, generators, speed sensors, air-core bobbin gages, encoders, and stepper motors,

Grade: IMND-650 

This TyTek grade provides excellent properties and outstanding performance combined with exceptional dimensional tolerances. Bonded magnets utilizing NdFeB powders are produced in conjunction with quality thermoplastic resins. The compound of thermoplastic resin and magnetic powder is then injection molded. This process yields a dimensionally precise part with consistent high magnetic energy. Dimensional tolerances are typically ±.003"/inch or ±.002" whichever is greater. Tighter tolerances are negotiable.

Torque drives, airbag crash sensors, fractional HP motors, generators, speed sensors, air-core bobbin gauges, encoders and stepper motors are just some of the typical applications.

Flexible Bonded SmCo 

Grade: FBSC-350 

TyTek’s FBSC-350 magnets are flexible, rubber-like, bonded SmCo composite magnets that combine superior magnetic properties with flexibility and exceptional temperature coefficients. These materials are not only highly resistant to demagnetization, but they can also be manufactured in cut pieces or continuous lengths. Rubber bonded magnets utilizing SmCo powders are produced in conjunction with quality natural and/or synthetic rubbers. The compound of rubber materials and magnetic powder is then extruded in a die to the desired cross sectional geometry. This process delivers good dimensional characteristics with consistent, homogeneous magnetic properties. Standard as formed dimensional tolerances are typically ±.005" on thickness, ±.015" on width, and ±.01 5" or ±0.5%, whichever is greater on length. Tighter tolerances are negotiable.

Typical applications include speed sensors, position sensors, rotary sensors, and linear output sensors.

Injection Molded Sm2Co17 

Grade: IMSC-650 

The magnets we produce in IMSC-650 possess excellent properties and outstanding performance. Those characteristics are combined with exceptional dimensional tolerances. Bonded magnets utilizing Sm2Co17 powders are produced in conjunction with quality thermoplastic resins. The compound of thermoplastic resin and magnet¬ic powder is then injection molded. This process yields a dimensionally precise part with consistent high magnetic energy and excellent temperature stability over the recommended service range. Dimensional tolerances are typically ±.003"/inch or ±.002" whichever is greater.

Typically, the applications for these magnets include fractional HP motors, speed sensors, spindle motors, encoders, and stepper motors.

Grade: IMSC-950 

Grade IMSC-950 magnets provide excellent properties and outstanding performance combined with exceptional dimensional tolerances. Bonded magnets utilizing Sm2Co17 powders are produced in conjunction with quality thermoplastic resins. The compound of thermoplastic resin and magnet¬ic powder is then injection molded. This process yields a dimensionally precise part with consistent high magnetic energy and excellent temperature stability over the recommended service range. Dimensional tolerances are typically ±.003"/inch or ±.002" whichever is greater.

Fractional HP motors, spindle motors, speed sensors, linear and rotary sensors, and stepper motors are among the typical applications for these magnets.