Our plastic bonded NdFeB magnet technology offers the highest magnetic energy density available in bonded form, making them ideal for compact and high-efficiency designs. The plastic bonded SmFeN magnet technology represents a newer class of rare-earth magnets. This technology offers a substantial improved combination of thermal stability, corrosion resistance and environmental robustness.
What are plastic bonded NdFeB magnets?
Plastic Bonded NdFeB magnets are manufactured by binding rapidly-quenched nanocrystalline NdFeB powder with polymer binders. These plastic bonded magnets have an isotropic material structure. Different types of binders can be used depending on the requirements. Several techniques for producing plastic bonded NdFeB magnet types are available.
One of the greatest strengths of plastic bonded magnet technology is design integration.
Magnets can be molded directly into functional components, allowing:
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Integration with shafts, gears, and housings
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Reduced part count and assembly steps
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Improved positional accuracy and repeatability
Plastic bonded magnet technologies also contribute to more sustainable manufacturing by:
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Maximizing material utilization with minimal waste
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Enabling recycling of production scrap
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Reducing dependency on heavy rare earth elements
Compression moulding
After mixing the nanocrystalline NdFeB powder with a polymer binder the material is filled into a mould and pressed. Different magnet shapes can be produced with this technology. Due to the high NdFeB content magnets with a Remanence (Br) between ~570-770 mT can be produced depending on the selected grade.
The magnets will be coated to obtain a smooth and even protection layer. Several coating techniques are available depending on the application.
Injection moulding
This manufacturing technique is particular effective for larger volume production with higher product design freedom and for more severe applications. Though the Remanence (Br) of the products is slightly lower than those made with compression moulding, between ~410-720 mT, because of their lower content of NdFeB powder. As almost any shape can be obtained, this technique is especially suitable for complex shapes. This results in optimized performance, smooth magnetic flux, and highly repeatable quality all ideal for precision applications.
Advanced technologies like overmoulding and 2-shot moulding are possible with this technique. Below you can find an explanation of both technologies.
Overmoulding
Using this injection moulding technique inserts can be overmoulded with magnetic material and/or technical plastic. In this way magnets can be combined with shaft, lamination stack, holder or other functional elements. By using high-end equipment and sophisticated mould designs it is possible to keep very strict specifications.
2-shot moulding
2-shot moulding technology makes it possible to connect magnet material together with several plastics and/or metal parts. This all is done in a single injection moulding process. Advantages of this technique are:
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High precision, all parts are fitted in one injection moulding process.
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Combine different functionalities in one part.
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Better adhesion between magnet and plastic, as these components are chemically connected.
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Elimination of assembly steps.
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Reduction of costly handling and reducing risks.
Plastic bonded SmFeN magnets
SmFeN magnet powders are produced in a similar way to NdFeB. However with SmFeN nitrogen is diffused by heat treatment (nitriding) into the rapidly quenched SmFe flakes. These flakes are then mixed with a polymer binder and can then be processed either by compression moulding or injection moulding to make isotropic plastic bonded SmFeN magnets.
The magnetic performance of SmFeN plastic bonded magnets is higher compared to plastic bonded NdFeB magnets. Besides this it has excellent corrosion- and heat-resistance behaviour which makes it suitable for demanding applications. In a world looking for smarter and more sustainable technologies, SmFeN magnets quietly stand out as a powerful solution shaped by high-end materials engineering.
Laminating package plastic bonded NdFeB / SmFeN Magnet Technology
With the lamination technology (stamping process) in house, this is a perfect solution for overmoulding technology and forcing flux more into the system. In this way magnet material can be combined with shaft and lamination stack together. By using high-end equipment and sophisticated mould designs it is possible to keep very strict specifications and imbalance tolerances. It combines the flexibility of bonded magnets with the efficiency of laminated electrical steel, creating a solution that is both powerful and precisely controllable. The laminated steel stack—built from thin, insulated layers of electrical steel—plays a crucial role. By breaking the steel into laminations, eddy current losses are dramatically reduced, improving efficiency and minimizing heat generation, especially in rotating or high-frequency applications. This means quieter operation, better thermal behavior, and longer service life.
Our magnet applications
Our advanced permanent magnet technologies offer solutions for a wide range of performance requirements. Hot formed magnet technology provides high strength and efficiency. Plastic bonded magnet technology offers design flexibility and consistent quality for complex shapes. SmCo magnet technology delivers stable performance in high-temperature and demanding environments. Together these technologies support reliable, efficient and innovative applications across modern industries.
